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03D224/280/355PM-1 Aisin Gas Heat Pump Multi-Unit Model P224/P280/P355 SERVICE MANUAL Type of Gas Type of Fuel Gas 13A 12A Propane Gas TGMP224B2N TGMP280B2N TGMP355B2N TGMP224B2P TGMP280B2P TGMP355B2P Salt-damage proof type TGMP224B2NE TGMP280B2NE TGMP355B2NE TGMP224B2PE TGMP280B2PE TGMP355B2PE Winterized type TGMP224B2NH TGMP280B2NH TGMP355B2NH TGMP224B2PH TGMP280B2PH TGMP355B2PH TGMP224B2NEH TGMP280B2NEH TGMP355B2NEH TGMP224B2PEH TGMP280B2PEH TGMP355B2PEH Specifications Standard Salt-damage proof/ Winterized type Note: Products of the salt-damage proof/winterized specifications are produced only on an order basis. AISIN SEIKI CO., LTD. AISIN Aisin gas heat pump PREFACE Safety Precautions The safety precautions to be strictly observed in order to avoid possible damage to persons engaged in the maintenance of the multi-unit P224/P280/P355 and to other persons, are described using the following methods: In this manual, hazards and damage likely to result from improper maintenance operations are WARNING” and “ CAUTION”. Be absolutely certain to represented using the markings “ observe these warnings and precautions. [Meaning of Markings] WARNING This marking is followed by a description of the situation in which failure to observe this warning could result in personal death or serious injury. CAUTION This marking is followed by a description of the situation in which failure to observe this precaution could lead to personal injury and/or product damage. )Before starting maintenance operations: WARNING 1. Turn off the leakage current circuit breaker located inside the control box of the outdoor unit. – Failure to observe this warning may result in electrical shock. 2. Close the fuel gas cock. – Fuel gas leakage may induce gas poisoning and/or gas explosion. ) During maintenance: WARNING 1. Wear the clothes that fit the nature of the work. 2. Beware so as not to touch hot sections or rotating bodies. – Touching could result in burns or injury. 3. Do not apply a valve cleaner to hot sections when cleaning valves. – Failure to observe this warning may result in fire. ) About brazing operations: CAUTION For brazing, conduct nitrogen gas blowoff using the method specified in the relevant service manual. – Failure to observe this precaution could lead to pipeline clogging due to the occurrence of oxide scales. –1– CONTENTS Page 1. SPECIFICATIONS ............................................................................................................. 1-1 1.1 Product External Views ...........................................................................................................................1-2 1.2 Product Specification ...............................................................................................................................1-3 1.2.1 Model Number and Product Name.......................................................................................1-3 1.2.2 Combination of Indoor Unit and Outdoor Unit....................................................................1-4 1.2.3 Structure Drawing ................................................................................................................1-7 1.2.4 Outdoor Unit Specifications .................................................................................................1-8 1.3 Outside Drawing of Outdoor Unit .........................................................................................................1-14 1.4 Outdoor Unit Internal Structure............................................................................................................1-16 1.5 Various Characteristics..........................................................................................................................1-18 1.5.1 Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities........................................................................................................1-18 1.5.2 Allowable Cooling and Heating Temperature Ranges .......................................................1-21 1.5.3 Changes According to Piping Length.................................................................................1-22 1.5.4 Fuel Comsunption ..............................................................................................................1-23 1.5.5 Outdoor Unit Operating Sound Characteristics.................................................................1-26 1.6 System Flow Chart .................................................................................................................................1-29 1.6.1 Refrigerant Circulation Diagrams and Description...........................................................1-29 1.6.2 Coolant/Fuel/Air Circulation Diagrams and Description..................................................1-31 2. CONTROL ........................................................................................................................... 2-1 2.1 System Control Function List..................................................................................................................2-3 2.2 Remote Control Unit Functions ..............................................................................................................2-7 2.3 DIP Switches for Function Selection ......................................................................................................2-8 2.4 System Input/Output Specifications ......................................................................................................2-11 2.4.1 Indoor Unit Input/Output Specifications ............................................................................2-11 2.4.2 Outdoor Unit Input/Output Specifications..........................................................................2-13 2.5 Protection Units......................................................................................................................................2-15 2.5.1 Protection Units and Sensor Functions..............................................................................2-15 2.5.2 Sensor Mounting Positions.................................................................................................2-18 2.6 Outdoor Unit Electrical Wiring Diagrams ............................................................................................2-20 2.6.1 Outdoor Unit Electrical Wiring Diagram ..........................................................................2-20 2.6.2 Indoor Unit Wiring Diagram..............................................................................................2-23 3. TROUBLE DIAGNOSIS AND REPAIR............................................................................ 3-1 3.1 Circuit Base Board Maintenance Functions ..........................................................................................3-2 3.2 Trouble Items and Diagnosis .................................................................................................................3-19 3.2.1 Error Codes, Contents, and Major Likely Causes..............................................................3-19 –2– AISIN Aisin gas heat pump 3.3 Diagnostic Items.....................................................................................................................................3-27 3.4 Trouble Diagnosis and Check ...............................................................................................................3-30 3.4.1 If the System Does Not Operate..........................................................................................3-30 3.4.2 If the Starter Does Not Operate..........................................................................................3-32 3.4.3 If the Engine Does Not Start...............................................................................................3-34 3.4.4 If the Engine Stalls .............................................................................................................3-39 3.4.5 Coolant Temperature Alarms .............................................................................................3-41 3.4.6 Oil Pressure Alarms ...........................................................................................................3-44 3.4.7 Engine Speed Too High Alarm ...........................................................................................3-45 3.4.8 High-Pressure Alarms During Cooling..............................................................................3-46 3.4.9 High-Pressure Alarms During Heating..............................................................................3-49 3.4.10 Refrigerant Low-Pressure Alarms......................................................................................3-51 3.4.11 Refrigerant Discharge Temperature Alarms ......................................................................3-53 3.4.12 Communications Trouble and Indoor Unit Circuit Trouble...............................................3-55 3.4.13 If Sufficient Cooling Cannot Be Obtained ..........................................................................3-57 3.4.14 If Sufficient Heating Cannot Be Obtained ..........................................................................3-59 4. MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS.................................... 4-1 4.1 Engine Body Replacement.......................................................................................................................4-2 4.2 Cylinder Head Replacement ....................................................................................................................4-4 4.3 Compressor Replacement.........................................................................................................................4-7 5. PERIODIC MAINTENANCE........................................................................................... 5-1 5.1 Periodic Maintenance Items and Periods................................................................................................5-2 5.2 Periodic Maintenance Procedures...........................................................................................................5-3 5.2.1 Changing Engine Oils ..........................................................................................................5-3 5.2.2 Replacing the Oil Filter........................................................................................................5-3 5.2.3 Replacing an Ignition Plug...................................................................................................5-3 5.2.4 Replacing the Air Element....................................................................................................5-4 5.2.5 Replacing the Compressor Belt ............................................................................................5-4 5.2.6 Adjusting the Valve Clearances............................................................................................5-5 5.2.7 Adding Coolant and Coolant Reinforcement........................................................................5-5 5.2.8 Checking the Coolant Hosing...............................................................................................5-5 5.2.9 Checking the Compressor.....................................................................................................5-6 5.2.10 Checking the Operational Sounds ........................................................................................5-6 5.2.11 Prevention of Valve Damage................................................................................................5-6 5.2.12 Replacing the Fuel Gas Hose ...............................................................................................5-6 –3– 6. MAINTENANCE DATA STANDARDS........................................................................... 6-1 6.1 Engine-Related Components ...................................................................................................................6-2 6.2 Refrigerant-Related Components ............................................................................................................6-4 6.3 Electrical Equipment ...............................................................................................................................6-5 6.4 Coolant-Related Components ................................................................................................................6-10 6.5 Thermister Characteristics.....................................................................................................................6-11 –4– AISIN Aisin gas heat pump 3 SPECIFICATIONS Chapter 1 SPECIFICATIONS 1.1 1.2 Product External Views Product Specification 1.2.1 Model Number and Product Name 1.2.2 Combination of Indoor Unit and Outdoor Unit 1.2.3 Structure Drawing 1.2.4 Outdoor Unit Specifications 1.3 1.4 1.5 Outside Drawing of Outdoor Unit Outdoor Unit Internal Structure Various Characteristics 1.5.1 Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities 1.5.2 Allowable Cooling and Heating Temperature Ranges 1.5.3 Changes According to Piping Length 1.5.4 Fuel Consumptions 1.5.5 Outdoor Unit Operating Sound Characteristics 1.6 System Flow Chart 1.6.1 Refrigerant Circulation Diagrams and Description 1.6.2 Coolant/Fuel/Air Circulation Diagrams and Description 1-1 1 SPECIFICATIONS 1.1 Product External Views 4-/3-/2-way cassette type 4-/3-/2-way compact cassette type 2-way cassette type FTKTPOOOM5 TKTCPOOOM5 TKTWPOOOM5 1-way cassette type Built-in cassette type Ceiling-embedded high static-pressure duct type TKTSPOOOM5 TKRPOOOM5 TKUPOOOM5 Ceiling-embedded medium static-pressure duct type Wall-mounted type Floor-standing lowboy exposed type TKUMPOOOM5 TKKPOOOM5 TKFLPOOOM5 Floor-standing lowboy concealed type Ceiling-suspended type Floor-standing type TKFUPOOOM5 TKEPOOOM5 TKFPOOOM5 Outdoor unit TGMP224/280/355** (Note 1) Notes: 1. The double-asterisk symbol (**) denotes a serial code number and differ according to the type of gas used. 2. The triple circle mark (ooo) in model numbers denote a capacity. 3. Other than above, outside-air processing unit with a direct expansion coil unit, air feed processing unit, ceiling-suspended oil-resisting type, floor-standing plenum type, and floor-standing duct type are available. 1-2 AISIN Aisin gas heat pump 1.2 Product Specification 1.2.1 Model Number and Product Name (1) Product name Gas heat pump air conditioner outdoor unit (2) Model number New Refrigerant Building-Use Multi-Unit Model P224 New Refrigerant Building-Use Multi-Unit Model P280 New Refrigerant Building-Use Multi-Unit Model P355 TGMP224∗∗∗ TGMP280∗∗∗ TGMP355∗∗∗ [Description of outdoor unit model number] Example: LPG specification(salt-damage proof type); TGMP280B2NE T G Outdoor unit M P 2 Type 8 0 Capacity (kW) S: Single M: Building-use multi-type N: Store-use multi-type Refrigerant P: R407C Capacity 224: 22.4 kW 280: 28.0 kW 355: 35.5 kW B 1 Model change additional No. (in alphabetical order) N E Minor change additional No. (in numerical order) Gas type N: 13A, 12A P: Propane gas type A C: Low-calorie gas type A Special specification E: Salt-damage proof type H: Winterized type * Blank for standard specifications [Description of serial number] 0 0 1 0 0 1 0 1 4 0 Assign a serial number beginning with “00100101”. [Description of indoor unit model number] T K Indoor unit T W Type T: 4-way cassette type TC: 4-way compact cassette type TW: 2-way cassette type TS: 1-way cassette type R: Built-in cassette type U: High static-pressure duct type UM: Medium staticpressure duct type E: Ceiling-suspended type K: Wall-mounted type FL: Floor-standing lowboy (exposed) P 1 M Capacity (kW) FU: Floor-standing lowboy (concealed) SA: Outside-air processing unit with a direct expansion coil unit US: Air feed processing unit ES: Ceiling-suspended oilresisting type FP: Floor-standing plenum type FD: Floor-standing duct type F: Floor-standing type RC: Remote control unit * (blank): Closer to left 1-3 5 Type of outdoor Serial No. for unit connected design Example: 280: 28 kW 140: 14 kW 90: 9 kW 71: 7.1 kW 45: 4.5 kW * Omitted for remote control units S: Js series M: Jm series * Design-serial No. for remote control units 1 SPECIFICATIONS 1.2.2 Combination of Indoor Unit and Outdoor Unit (1) Model P224 outdoor unit (TGMP224∗∗∗) P22 P28 P36 P45 P56 P71 P80 P90 P112 P140 2.2 (kW) 2.8 (kW) 3.6 (kW) 4.5 (kW) 5.6 (kW) 7.1 (kW) 8.0 (kW) 9.0 (kW) 11.2 (kW) 14.0 (kW) 16.0 (kW) 4-/3-/2-way cassette type TKT { { { { { { { { { { 4-/3-/2-way compact cassette type TKTC { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { Model No. Type 2-way cassette type TKTW { 1-way cassette type TKTS Built-in cassette type TKR Ceiling-embedded high static-pressure duct type TKU Ceiling-embedded medium static-pressure duct type TKUM { { { Ceiling-suspended type TKE Wall-mounted type TKK Floor-standing lowboy (exposed) TKFL Floor-standing lowboy (concealed) TKFU Outside-air processing unit with a direct expansion coil unit TKSA { P160 P224 P280 22.4 (kW) 28.4 (kW) { { { { { { { { { { { { { { { { Air feed processing unit TKUS { Ceiling-suspended oil-resisting type TKES Floor-standing plenum type TKFP { { { { Floor-standing duct type TKFD Floor-standing type TKF { Capacity available Outdoor unit capacity ratio: Approx. 50 to 130% (Total capacity of indoor units: P112 to P291) Number of connectable indoor units { 1 to 12 units Note: The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 100% outdoor unit capacity ratio. 1-4 AISIN Aisin gas heat pump (2) Model P280 outdoor unit (TGMP280∗∗∗) P22 P28 P36 P45 P56 P71 P80 P90 P112 P140 P160 P224 P280 2.2 (kW) 2.8 (kW) 3.6 (kW) 4.5 (kW) 5.6 (kW) 7.1 (kW) 8.0 (kW) 9.0 (kW) 11.2 (kW) 14.0 (kW) 16.0 (kW) 4-/3-/2-way cassette type TKT { { { { { { { { { { 4-/3-/2-way compact cassette type TKTC { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { Model No. Type 2-way cassette type TKTW { 1-way cassette type TKTS Built-in cassette type TKR { Ceiling-embedded high static-pressure duct type TKU Ceiling-embedded medium static-pressure duct type TKUM { { Ceiling-suspended type TKE Wall-mounted type TKK { Floor-standing lowboy (exposed) TKFL { { { { Floor-standing lowboy (concealed) TKFU { { { { Outside-air processing unit with a direct expansion coil unit TKSA { { { 22.4 (kW) 28.4 (kW) { { { { { { { Air feed processing unit TKUS { Ceiling-suspended oil-resisting type TKES { Floor-standing plenum type TKFP { { { Floor-standing duct type TKFD Floor-standing type TKF { Capacity available Outdoor unit capacity ratio: Approx. 50 to 130% (Total capacity of indoor units: P140 to P364) Number of connectable indoor units { 1 to 12 units Note: The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 100% outdoor unit capacity ratio. 1-5 1 SPECIFICATIONS (3) Model P355 outdoor unit (TGMP355∗∗∗) P22 P28 P36 P45 P56 P71 P80 P90 P112 P140 P160 P224 P280 2.2 (kW) 2.8 (kW) 3.6 (kW) 4.5 (kW) 5.6 (kW) 7.1 (kW) 8.0 (kW) 9.0 (kW) 11.2 (kW) 14.0 (kW) 16.0 (kW) 4-/3-/2-way cassette type TKT { { { { { { { { { { 4-/3-/2-way compact cassette type TKTC { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { Model No. Type 2-way cassette type TKTW { 1-way cassette type TKTS Built-in cassette type TKR { Ceiling-embedded high static-pressure duct type TKU Ceiling-embedded medium static-pressure duct type TKUM { { Ceiling-suspended type TKE Wall-mounted type TKK { Floor-standing lowboy (exposed) TKFL { { { { Floor-standing lowboy (concealed) TKFU { { { { Outside-air processing unit with a direct expansion coil unit TKSA { { { 22.4 (kW) 28.4 (kW) { { { { { { { Air feed processing unit TKUS { Ceiling-suspended oil-resisting type TKES { Floor-standing plenum type TKFP { { { Floor-standing duct type TKFD Floor-standing type TKF { Capacity available Outdoor unit capacity ratio: Approx. 50 to 130% (Total capacity of indoor units: P178 to P462) Number of connectable indoor units { 1 to 12 units Note: The capabilities of indoor units slightly decrease during the simultaneous operation of these units in excess of a 100% outdoor unit capacity ratio. 1-6 AISIN Aisin gas heat pump 1.2.3 Structure drawing Refrigerant pipe Signal wire Electrical wire Power supply Single phase 200V Or three phase 200V Indoor unit Indoor unit Overcurrent breaker Drain pipes VP25 Drain pipes VP25 Remote controller Outdoor unit Indoor unit Remote controller Remote controller Indoor unit Note Outdoor unit Class-three Ground Exhaust drain pipes Single phase 200V Three phase 200V Single phase 200V ○ × Three phase 200V × ○ Wiring power supply from outdoor unit (possible to wire separately) × wiring separately Refrigerant gas pipe TGMP224B 25 4 TGMP280B 28 58 TGMP355B 31.8 Fuel gas pipe R3/4 Refrigerant liquid pipe φ12.7 Electrical wire and signal wire inlet Condensation drain Drain pipes VP25 Exhaust air drain hose Connecting position for piping wiring (Rear side of outdoor unit) 1-7 1 SPECIFICATIONS 1.2.4 Outdoor unit Specification City gas 13A (12A) specifications TGMP224B2N Cooling rating Scroll type×2 P224 Multi for building Exclusion capacity L/rev 0.0605X2 22.4 Revolution range min-1 (cooling) 2280 to 3085 min-1 (heating) 2280 to 3895 kW Heating rating Outer dimensions Operating Sound 26.5 dB Normal 53, Silent Mode 51 Refrigerator oil enclosure q’ty Width 1398 Power transfer method Poly V-belting Depth 798 Type R407C Sealing amount 13 Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin 3.6GY 8.0/0.9 DIC546 1/2 4 V Single phase 200 / Three phase 200 Starting current A 20 Running current (A) Cooling 3.9/4.7, 2.3/2.7 Heating 4.0/4.7, 2.3/2.7 Air suction port Front and rear side Power consumption (kw) Cooling 0.74/0.90 Air blowing port Upper Heating 0.76/0.92 Exhaust heat absorption Heating refrigerant in double pipe Cooling 95/96, 93/96 Heating 95/98, 95/98 Cooling kW Heating 18.6 17.5 Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type L 0.952 Rated output kW 7.5 Revolution range min-1 Lubrica ting oil Exhaust volume Type Capacity (Cooling) 1200 to 1650 L Type Refrigeran t piping Liquid pipe mm Gas pipe Propeller fan ×2 210 Single-phase induction motor (8P) 180X2 φ12.7 flare connection φ25.4 flange connection Fuel gas pipe R 3/4 Exhaust drain pipe mm φ15 (Heating) 1200 to 2050 35 Upper side Aisin Coolant S Sealing amount L 14 Concentration % 65 Freezing temperature °C -35 Type Pump Type × Number of units Rated air 3 m /min amount Type Motor Rated W output Aisin GHP Oil L10000 Exhaust port position Motor output Pipe dimensions Power ratio(%) Fan Power source Cons umption Fuel L Heat exchanger Exterior color (DIC) Electricity characteristics 530 Engine NL10 1866 Mass Engine coolant Specified refrigerator oil Height Refrigerant Capability Type Type × Number of units Compressor Model No. (50/60HZ) W 125 (Equivalent length) Permissible pipe length 100 (Actual length) Permissible difference in elevation between indoor/outdoor unit m 50(Outdoor unit at top) 40(Outdoor unit at bottom) Permissible difference in elevation between indoor units 15 number 1 to 12 Magnet type spiral pump Connectable indoor units capacity P22 to P224 105/150 Legal freezing capacity RT 2.3 Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-8 AISIN Aisin gas heat pump Propane gas specifications (50/60HZ) TGMP224B2P Cooling rating Scroll type×2 P224 Multi for building Exclusion capacity L/rev 0.0605X2 22.4 Revolution range min-1 (cooling) 2280 to 3040 min-1 (heating) 2280 to 3895 kW Heating rating Outer dimensions Operating Sound 26.5 dB Normal 53, Silent Mode 51 Refrigerator oil enclosure q’ty Width 1398 Power transfer method Poly V-belting Depth 798 Type R407C Sealing amount 13 Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin L 4 V Single phase 200 / Three phase 200 Starting current A 20 Running current (A) Cooling 3.9/4.7, 2.3/2.7 Heating 4.0/4.7, 2.3/2.7 Air suction port Front and rear side Power consumption (kw) Cooling 0.74/0.90 Air blowing port Upper Heating 0.76/0.92 Exhaust heat absorption Heating refrigerant in double pipe Cooling 95/96, 93/96 Heating 95/98, 95/98 Fuel Cons umption Power ratio(%) Cooling kW Heating 18.6 17.5 L 0.952 Rated output kW 6.0 Revolution range min-1 Lubrica ting oil Exhaust volume Type Capacity (Cooling) 1200 to 1600 (Heating) 1200 to 2050 Type × Number of units Rated air 3 m /min amount Type Motor Rated W output Liquid Refrigeran pipe mm t piping Gas pipe Propeller fan ×2 Fuel gas pipe R 3/4 Exhaust drain pipe mm 180 Single-phase induction motor (8P) 180X2 φ12.7 flare connection φ25.4 flange connection φ15 Aisin GHP Oil L10000 L 35 Exhaust port position Upper side Type Aisin Coolant S Sealing amount L 14 Concentration % 65 Freezing temperature °C -35 Type Motor output Pipe dimensions Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type Pump Fan Power source Heat exchanger Exterior color (DIC) 3.6GY 8.0/0.9 DIC546 1/2 Electricity characteristics 530 Engine NL10 1866 Mass Engine coolant Specified refrigerator oil Height Refrigerant Capability Type Type × Number of units Compressor Model No. W 125 (Equivalent length) Permissible pipe length 100 (Actual length) Permissible difference in elevation between indoor/outdoor unit m 50(Outdoor unit at top) 40(Outdoor unit at bottom) Permissible difference in elevation between indoor units 15 number 1 to 12 Magnet type spiral pump Connectable indoor units capacity P22 to P224 105/150 Legal freezing capacity RT 2.3 Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-9 1 SPECIFICATIONS City gas 13A (12A) specifications Model No. TGMP280B2N P280 Multi for building Heating rating Outer dimensions Operating Sound kW dB 28.0 33.5 Normal 57, Silent Mode 55 L/rev 0.0605X2 Revolution range min-1 (cooling) 2280 to 4085 min-1 (heating) 2280 to 4845 Specified refrigerator oil NL10 Width 1398 Power transfer method Poly V-belting Depth 798 Type R407C Sealing amount 13 Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin 3.6GY 8.0/0.9 DIC546 1/2 L 4 V Single phase 200 / Three phase 200 Starting current A 20 Running current (A) Cooling 5.0/5.9, 2.9/3.4 Heating 5.3/6.1, 3.1/3.5 Air suction port Front and rear side Powerconsumption (kw) Cooling 0.96/1.15 Air blowing port Upper Heating 1.01/1.19 Exhaust heat absorption Heating refrigerant in double pipe Cooling 96/97, 96/98 Type × Number of units Propeller fan ×2 95/98, 94/98 Rated air amount m /min 210 Type Single-phase induction motor (8P) Power ratio(%) Consu mption Heating Cooling 24.5 Motor kW Heating 22.4 L 0.952 Rated output kW 7.5 Revolution range min-1 Lubricat ing oil Exhaust volume Type Capacity (Cooling) 1200 to 2150 (Heating) 1200 to 2550 Refrigeran t piping 3 Rated output W Liquid pipe mm Gas pipe 220X2 φ12.7 flare connection φ28.58 flange connection Fuel gas pipe R 3/4 Exhaust drain pipe mm φ15 Aisin GHP Oil L10000 L Exhaust port position Type 35 Upper side Aisin Coolant S Sealing amount L 15.5 Concentration % 65 Freezing temperature °C -35 Type Motor output Pipe dimensions Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type Pump Fan Power source Heat exchanger Exterior color (DIC) Electricity characteristics Exclusion capacity Refrigerator oil enclosure q’ty 560 Fuel Scroll type×2 2118 Mass Engine Type × Number of units Height Refrig erant Capa bility Cooling rating Compressor Type Engine coolant (50/60HZ) W 125 (Equivalent length) Permissible pipe length 100 (Actual length) Permissible difference in elevation between indoor/outdoor unit m 50(Outdoor unit at top) 40(Outdoor unit at bottom) Permissible difference in elevation between indoor units 15 number 1 to 12 Magnet type spiral pump Connectable indoor units capacity P22 to P280 105/150 Legal freezing capacity RT 3.0 Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 862. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-10 AISIN Aisin gas heat pump Propane gas specifications (50/60HZ) TGMP280B2P Type Scroll type×2 P280 Multi for building Exclusion capacity L/rev 0.0605X2 28.0 Revolution range min-1 (cooling) 2280 to 4085 min-1 (heating) 2280 to 4845 kW Heating rating Outer dimensions Operating Sound 33.5 dB Normal 57, Silent Mode 55 Refrigerator oil enclosure q’ty Width 1398 Power transfer method Poly V-belting Depth 798 Type R407C Sealing amount 13 Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin Exterior color (DIC) 3.6GY 8.0/0.9 DIC546 1/2 20 Running current (A) 5.0/5.9, 2.9/3.4 Heating 5.3/6.1, 3.1/3.5 Air suction port Front and rear side Cooling 0.96/1.15 Air blowing port Upper Heating 1.01/1.19 Exhaust heat absorption Heating refrigerant in double pipe Cooling 96/97, 96/98 Type × Number of units Propeller fan ×2 Heating 95/98, 94/98 Rated air amount m /min 210 Type Single-phase induction motor (8P) Power consumption (kw) Power ratio(%) V Cooling Single phase 200 / Three phase 200 24.5 kW Heating Motor 22.4 L 0.952 Rated output kW 7.5 Revolution range min-1 Lubrica ting oil Exhaust volume Type Capacity (Cooling) 1200 to 2150 (Heating) 1200 to 2550 Refrigeran t piping 3 Rated output Liquid pipe W mm Gas pipe 220X2 φ12.7 flare connection φ28.58 flange connection Fuel gas pipe R 3/4 Exhaust drain pipe mm φ15 Aisin GHP Oil L10000 L Exhaust port position Type 35 Upper side Aisin Coolant S Sealing amount L 15.5 Concentration % 65 Freezing temperature °C -35 Type Motoroutput Pipe dimensions Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type Pump Fan A Cooling Consum ption Electricity characteristics 4 Starting current Power source Fuel L Heat exchanger 560 Engine NL10 2118 Mass Engine coolant Specified refrigerator oil Height Refrig erant Capability Cooling rating Type × Number of units Compressor Model No. W 125 (Equivalent length) Permissible pipe length 100 (Actual length) Permissible difference in elevation between indoor/outdoor unit Permissible difference in elevation between indoor units m 50(Outdoor unit at top) 40(Outdoor unit at bottom) 15 number 1 to 12 Magnet type spiral pump Connectable indoor units capacity P22 to P280 105/150 Legal freezing capacity RT 3.0 Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-11 1 SPECIFICATIONS 13A (12A) specifications Cooling rating 35.5 kW Heating rating 42.5 kW 58 dB (56 dB in silent mode) Height 2118 mm Width 1398 mm Depth 798 mm Mass 560 kg Exterior color [Munsell] 3.6GY8.0/9.0 or equivalent DIC546 1/2 Revolution range Specified refrigerator oil Refrigerator oil enclosure q’ty Power transfer method Refrigerant Operating sound Heat exchanger Capability Exclusion capacity New Refrigerant Model P355 Building-Use Multi-Unit Type Outer dimensions Type × Number of units TGMP355B2N Compressor Model No. Type –1 2280 to 4655 min (Cooling) –1 2280 to 4845 min (Heating) NL10 4L Poly V-belting Enclosure q’ty 13 kg Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin Front and rear Air blowing port Top Running current 5.0/5.9, 2.9/3.4 A (Cooling) 5.3/6.1, 3.1/3.5 A (Heating) Electrical characteristics Air suction port 20 A 0.961.15 kW (Cooling) 1.10/1.19 kW (Heating) Type × Number of units Power ratio 96/97, 96/98% (Cooling) 95/98, 94/98% (Heating) Rated air amount Fuel 200 V single-phase Starting current Power consumption Consumption 29.9 kW (Cooling rating) 29.6 kW (Heating rating) Fan Exhaust heat collection method Motor 952 cm Rated output 9.5 kW –1 Revolution range Lubricating oil type 1200 to 2450 min (Cooling) –1 1200 to 2550 min (Heating) Aisin Gas Engine Oil (L10000) Pipe dimensions 3 Exhaust volume Type Rated output Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type Engine 3 R407C Power source Refrigerant piping Refrigerant heating Propeller fan × 2 3 210 m /min Single-phase induction motor (6P) 0.22 kW Liquid pipe φ12.7 mm Flare-connected Gas pipe φ31.8 mm Flange-mounted Fuel gas pipe Exhaust drain pipe Permissible pipe length R3/4 φ15 mm 125 m (Equivalent length) 100 m (Actual length) 50 m (Outdoor unit upper) Lubricating oil enclosure q’ty 35 L Permissible difference in elevation between indoor/outdoor units Exhaust port position Top Permissible difference in elevation between indoor units 15 m Number of indoor units which can be combined 1 to 12 units (Capacity: P22 to P280) Type Aisin Coolant S Enclosure q’ty Concentration Freezing temperature Pump Coolant Scroll type × 2 60.5 cm /rev × 2 Type Motor rated output 15.5 L 50% Legal freezing capacity 40 m (Outdoor unit lower) 3.4 RT –35°C Magnet type spiral pump (50/60 Hz) 0.105/0.150 kW Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-12 AISIN Aisin gas heat pump Class-A propane gas specifications Cooling rating 35.5 kW Heating rating 42.5 kW 2118 mm Width 1398 mm Depth 798 mm Mass 560 kg Exterior color [Munsell] Revolution range Specified refrigerator oil Power transfer method 58 dB (56 dB in silent mode) Height Refrigerant Operating sound 3.6GY8.0/9.0 or equivalent DIC546 1/2 Type Enclosure q’ty 2280 to 4655 min (Cooling) –1 2280 to 4845 min (Heating) NL10 4L Poly V-belting 13 kg Outdoor unit heat exchanger Slit fin Exhaust gas heat exchanger Multi-pipe heat exchanger Engine radiator Louver fin Front and rear Starting current 20 A Air blowing port Top Running current 5.0/5.9, 2.9/3.4 A (Cooling) 5.3/6.1, 3.1/3.5 A (Heating) Electrical characteristics Air suction port 0.95/1.15 kW (Cooling) 1.10/1.19 kW (Heating) Type × Number of units Power ratio 96/97, 96/98% (Cooling) 95/98, 94/98% (Heating) Rated air amount Fuel 200 V single-phase Power consumption Consumption 29.9 kW (Cooling rating) 29.6 kW (Heating rating) Exhaust volume Rated output 952 cm 3 9.5 kW –1 Revolution range Lubricating oil type Lubricating oil enclosure q’ty Exhaust port position Type Aisin Gas Engine Oil (L10000) Concentration Freezing temperature Type Motor rated output Fan Motor Type Rated output Refrigerant piping Refrigerant heating Propeller fan × 2 3 210 m /min Single-phase induction motor (6P) 0.22 kW Liquid pipe φ12.7 mm Flare-connected Gas pipe φ31.8 mm Flange-mounted Fuel gas pipe Exhaust drain pipe Permissible pipe length R3/4 φ15 mm 125 m (Equivalent length) 100 m (Actual length) 50 m (Outdoor unit upper) 35 L Permissible difference in elevation between indoor/outdoor units Top Permissible difference in elevation between indoor units 15 m Number of indoor units which can be combined 1 to 12 units (Capacity: P22 to P280) Aisin Coolant S Enclosure q’ty Pump 1200 to 2450 min (Cooling) –1 1200 to 2550 min (Heating) Exhaust heat collection method Pipe dimensions Water-cooled vertical type, 4-cycle, 3-cylinder OHV Type Engine 3 R407C Power source Coolant Scroll type × 2 60.5 cm /rev × 2 –1 Refrigerator oil enclosure q’ty Heat exchanger Capability Exclusion capacity New Refrigerant Model P355 Building-Use Multi-Unit Type Outer dimensions Type × Number of units TGMP355B2P Compressor Model No. 15.5 L 50% Legal freezing capacity 40 m (Outdoor unit lower) 3.4 RT –35°C Magnet type spiral pump 0.105/0.150 kW (50/60 Hz) Notes: 1. The cooling/heating capability and electrical characteristics data shown in the above table was measured under the conditions of JIS B 8627. 2. The operating sound level shown in the above table was measured in an anechoic room, subject to the relevant provisions of JIS. Under actual conditions, the operating sound level shown above is usually exceeded since it is affected by ambient noise and the echoes of the installation room. 1-13 Hour meter 4-φ20 Anchor hole 4-φ20 Exhaust port (5) (4) φ30.0 1-14 (5) Power cable inlet (2) Refrigerant liquid pipe connecting port 1 position Exhaust drain hose with heating Power cable outlet R3/4 φ15.0 (3) For installing one unit Installation space For installing more than one unit Note: Provide a space of at least 800 mm if a snow hood is to be mounted. (3) Fuel pipe connecting port connecting port (1) Refrigerant gas pipe Condensate drain port Base Min. 2000 When installing four units or more, provide a maintenance space for every three units. Note: Provide a space of at least 800 mm if a snow hood is to be mounted. (4) Exhaust drain hose φ28.58 φ12.7 TGMP280 Exhaust drain hose Refrigerant liquid pipe (2) φ25.4 TGMP224 Fuel gas pipe Refrigerant gas pipe Description (1) Symbol (Note) (Note) 1.3 (Note) 1 SPECIFICATIONS Outside Drawing of Outdoor Unit (1) TGMP224B Hour meter 4-φ20 4-φ20 Anchor hole Description (5) (4) (5) (3) (4) 1-15 (5) Power cable inlet (2) Refrigerant liquid pipe connecting port Power cable outlet 1 position position ƒ1 30.0 Ó Exhaust drain hose with heating Exhaust drain hose Power cable outlet Exhaust drain hose with heating R3/4 φ15.0 Ó 15.0 ƒ φ30.0 Exhaust drain Fuel gashose pipe Symbol Refrigerant gas Description pipe Ó 28.58 TGMP280 ƒ (1)(1) φ31.8 Refrigerant gas pipe Ó 31.8 ƒ TGMP335 Refrigerant liquid pipe (2) φ12.7 Ó 12.7 ƒ (2) Refrigerant liquid pipe (3) R3/4 Fuel gas pipe Sym bol For installing one unit Installation space (Note) For installing more than one unit Note: Provide a space of at least 800 mm if a snow hood is to be mounted. (Note) (1) Refrigerant gas pipe connecting port Condensate drain port (4) Exhaust drain hose (3) Fuel pipe connecting port Min. 2000 Base When installing four units or more, provide a maintenance space for every three units. Note: Provide a space of at least 800 mm if a snow hood is to be mounted. (Note) Exhaust port Aisin gas heat pump AISIN (2) TGMP280/355B 1 SPECIFICATIONS 1.5 Outdoor Unit Internal Structure (2) (1) (3) (8) (9) (4) (10) (20) (11) (12) (13) (21) (14) (5) (22) (15) (16) (23) (6) (7) (17) (18) (19) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Exhaust port Radiator cap Reserve tank filling port Intake air silencer Air cleaner Oil filter Engine oil pressure switch Outdoor unit heat exchanger Radiator Gas mixer (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) Coolant temperature sensor Engine Discharge temperature sensor (L) Compressor (L) Compressor belt (L) Oil subtank Engine anti-vibration rubber (L) Oil pan Engine anti-vibration rubber (R) Electric three-way valve 1-16 (26) (21) (22) (23) (24) (25) (26) (24) (25) Control circuit board Exhaust heat exchanger Power supply unit Discharge temperature sensor (R) Compressor (R) Compressor belt (R) AISIN Aisin gas heat pump (1) (11) (2) (12) (13) (3) (4) (5) (6) (7) (8) (9) (10) (15) (14) (35) (16) (17) (18) (23) (24) (25) (26) (27) (19) (20) (28) (29) (21) (22) (32) (30) (31) (33) (34) (1) Discharge flexible tube (for capacity control) (2) Low-pressure switch (11) Discharge flexible tube (20) Accumulator (12) Intake flexible tube (21) Coolant pump (3) Accumulator inlet temperture sensor (4) Gas pipe temperature sensor (13) Intake temperature sensor (14) Ignition coil (22) Double-pipe heat exchanger (23) High-pressure sensor (5) Capacity regulating valve (15) Reserve tank (24) High-pressure switch (6) Liquid flow regulating valve (16) Outdoor fan (25) High-pressure service port (26) Oil-operated solenoid valve (27) Hot gas bypass valve (28) Terminal block (29) Filter drier (7) Heat exchanger liquid (17) temperature sensor (8) Low-pressure service port (18) (9) Four-way changeover valve (19) (10) Engine room temperature sensor (mounted on the top plate) Outside air temperature sensor Fan motor Filter drier 1-17 (37) (36) (30) Refrigerant liquid pipe connecting port (31) Refrigerant gas pipe connecting port (32) Drain filter (33) Engine anti-vibration rubber (rear) (34) Gas regulator (with gas electromagnetic valve) (35) Outdoor unit heat exchanger (36) Exhaust fan (37) Fuel gas hose 1 SPECIFICATIONS 1.5 1.5.1 Various Characteristics Cooling and Heating Capabilities and Gas Consumption for Each Indoor Unit Connection Capacities (1) TGMP224B2 Indoor Unit Connection Capacity Total Capabilities [kW] Gas Consumption [kW] New JIS Marking [kW] Cooling Heating Cooling Heating 291 29.1 23.8 27.2 19.3 16.4 280 28.0 23.7 27.1 19.3 16.6 270 27.0 23.6 27.0 19.1 16.8 260 26.0 23.3 26.9 19.0 16.9 250 25.0 23.1 26.8 18.9 17.0 240 24.0 22.7 26.7 18.8 17.2 230 23.0 22.5 26.6 18.7 17.4 224 22.4 22.4 26.5 18.6 17.5 220 22.0 22.0 26.0 18.3 17.2 210 21.0 21.0 24.9 17.5 16.6 200 20.0 20.0 23.7 16.7 15.9 190 19.0 19.0 22.5 16.0 15.3 180 18.0 18.0 21.3 15.4 14.6 170 17.0 17.0 20.2 15.1 14.0 160 16.0 16.0 19.0 14.9 13.6 150 15.0 15.0 18.0 14.6 13.4 140 14.0 14.0 17.0 14.2 13.3 130 13.0 13.0 15.6 16.5 13.1 120 12.0 12.0 14.3 15.2 12.9 112 11.2 11.2 13.2 14.1 13.8 1-18 AISIN Aisin gas heat pump (2) TGMP280B2 Indoor Unit Connection Capacity Total Capabilities [kW] Gas Consumption [kW] New JIS Marking [kW] Cooling Heating Cooling Heating 364 36.4 29.7 34.6 25.4 21.0 360 36.0 29.6 34.5 25.4 21.1 350 35.0 29.4 34.3 25.3 21.3 340 34.0 29.2 34.2 25.2 21.4 330 33.0 29.0 34.1 25.1 21.6 320 32.0 28.8 34.0 25.0 21.8 310 31.0 28.6 33.9 24.8 21.9 300 30.0 28.4 33.7 24.7 22.0 290 29.0 28.2 33.6 24.6 22.2 280 28.0 28.0 33.5 24.5 22.4 270 27.0 27.0 32.3 23.7 21.6 260 26.0 26.0 31.0 22.9 20.7 250 25.0 25.0 29.8 22.1 19.8 240 24.0 24.0 28.5 21.3 19.0 230 23.0 23.0 27.3 20.5 18.1 224 22.4 22.4 26.5 19.2 17.1 220 22.0 22.0 26.0 18.4 16.5 210 21.0 21.0 24.9 17.6 15.8 200 20.0 20.0 23.7 16.8 15.2 190 19.0 19.0 22.5 16.2 14.5 180 18.0 18.0 21.3 15.9 13.9 170 17.0 17.0 20.2 15.6 13.5 160 16.0 16.0 19.0 15.3 13.3 150 15.0 15.0 18.0 15.0 13.2 140 14.0 14.0 17.0 25.4 21.0 1-19 1 SPECIFICATIONS (3) TGMP355B2 Indoor Unit Connection Capacity New JIS Marking Total Capabilities [kW] Gas Consumption [kW] [kW] Cooling Heating Cooling Heating 461.5 46.15 37.8 43.9 31.1 27.8 450 45.0 37.6 43.7 31.0 28.0 440 44.0 37.5 43.6 30.8 28.2 430 43.0 37.4 43.5 30.7 28.4 420 42.0 37.1 43.3 30.6 28.5 410 41.0 36.8 43.2 30.5 28.6 400 40.0 36.6 43.1 30.4 28.8 390 39.0 36.3 43.0 30.3 29.0 380 38.0 36.1 42.9 30.2 29.2 370 37.0 35.8 42.7 30.1 29.3 360 36.0 35.6 42.6 30.0 29.5 355 35.5 35.5 42.5 29.9 29.6 340 34.0 34.0 40.6 28.4 28.3 330 33.0 33.0 39.3 27.4 27.4 320 32.0 32.0 38.1 26.4 26.5 310 31.0 31.0 36.9 25.4 25.7 300 30.0 30.0 35.8 24.4 24.8 290 29.0 29.0 34.7 23.4 24.0 280 28.0 28.0 33.5 22.4 23.1 270 27.0 27.0 32.3 21.7 22.2 260 26.0 26.0 31.0 21.0 21.4 250 25.0 25.0 29.8 20.2 20.4 240 24.0 24.0 28.5 19.5 19.6 230 23.0 23.0 27.3 18.7 18.7 224 22.4 22.4 26.5 17.9 18.0 220 22.0 22.0 26.0 17.6 17.7 210 21.0 21.0 24.9 16.8 17.0 200 20.0 2.0. 23.7 16.1 16.3 190 19.0 19.0 22.5 15.4 15.7 180 18.0 18.0 21.3 14.8 15.0 170 17.0 17.0 20.2 14.5 14.3 160 16.0 16.0 19.0 14.3 13.9 150 15.0 15.0 18.0 14.0 13.7 140 14.0 14.0 17.0 13.7 13.7 1-20 AISIN Aisin gas heat pump 1.5.2 Allowable Cooling and Heating Temperature Ranges (1) Cooling 40 30 Indoor intake air wet-bulb temperature 20 (WB°C) 24 Allowable cooling temperature range 14 –10 43 10 –20 –10 0 10 20 30 40 50 30 40 Outdoor intake air dry-bulb temperature (DB°C) (2) Heating 40 30 28 Indoor intake air dry-bulb temperature 20 (When the optional units are attached) (DB°C) Allowable heating temperature range 11 10 –20 –30 –20 15.5 –10 0 10 20 Outdoor intake air wet-bulb temperature (WB°C) Note: The temperature setting ranges of the remote control unit are listed in the table below. These temperature ranges slightly differ from the allowable operating temperature ranges of the system. Maximum Minimum Cooling 30 18 Heating 30 18 1-21 1 SPECIFICATIONS 1.5.3 Changes According to Piping Length (1) Cooling capacity Outdoor unit upper 50 0.90 40 0.92 0.94 30 Difference in elevation (m) 0.96 20 10 0.88 0.86 0.84 0.82 0.80 0.78 0.76 0.74 0.72 0.98 1.0 0 -10 Outdoor -20 unit lower -30 -40 10 20 30 40 50 60 70 80 90 Equivalent length (m) 100 110 120 (2) Heating capacity 50 Outdoor unit upper 0.96 0.93 40 0.97 30 0.98 20 Difference in elevation (m) 0.94 0.95 10 0.99 1.0 0 -10 -20 Outdoor unit lower -30 -40 10 20 30 40 50 60 70 Equivalent length (m) 1-22 80 90 100 110 120 AISIN Aisin gas heat pump Fuel consumption TGMP224B Cooling operation 35 30 25 30 35 40 25 22.4 20 dry-bulb 20 18.6 intake 40 15 (kW) Outdoor temperature 40 35 30 25 Fuel consumption (kw) 25 45 Cooling capacity (kw) 10 ( ) 5 0 (kW) 15 -5 14 16 18 19 20 22 24 Indoor intake wet-bulb temperature (WB ) (WB 26 28 Heating operation 16 20 24 40 16 20 24 30 26.5 (kW) Indoor intake dry-bulb temperature ( ) 50 20 17.5 (kW) 10 0 ( ) 20 -10 10 -20 -16 -12 -8 -4 0 4 6 8 12 Outdoor intake wet-bulb (DBtemperature WB (WB ) 1-23 16 20 Fuel consumption (kw) 30 60 Heating capacity (kw) 1.5.4 24 SPECIFICATIONS TGMP B Cooling operation 30 40 35 30 25 dry-bulb 50 24.5 20 Fuel consumption (kw) 60 (kW) 25 30 35 40 30 28.0 10 Outdoor intake temperature ( ) Cooling capacity (kw) 40 0 ( ) 20 -10 10 -20 (kW) 14 16 18 19 20 22 24 26 28 Indoor intake wet-bulb temperature ( (WB ) Heating operation 30.0 50.0 40.0 16 20 24 33.5 30.0 (kW) 22.4 (kW) 20.0 Indoor intake dry-bulb temperature ( ) 60.0 24 20 16 10.0 0.0 ( ) 20.0 -16 -12 -8 -4 0 Outdoor intake (WB ) 4 6 8 12 16 wet-bulb( temperature 1-24 20 Fuel consumption (kw) 40.0 70.0 Heating capacity (kw) 1 -10. 24 AISIN Aisin gas heat pump TGMP B Cooling operation Cooling capacity (kw) 50 dry-bulb 25 30 35 40 40 35.5 30 29.9 Outdoor intake temperature 60 (kW) 40 40 35 30 25 20 ( ) 0 20 -10 14 16 18 19 20 22 24 (kW) 10 30 26 Fuel consumption (kw) 70 28 Indoor intake wet-bulb temperature ( (WB ) Heating operation dry-bulb 16 20 24 Heating capacity (kw) 50 16 42.5 40 20 24 30 30 29.6 20 Indoor intake temperature ( ) 60 40 10 ( ) 0 (kW) 20 -16 -12 -10 -8 -4 0 4 6 8 12 16 Outdoor intake wet-bulb temperature ( (WB ) 1-25 20 24 Fuel consumption (kw) 70 (kW) 1 SPECIFICATIONS 1.5.5 Outdoor unit operating sound characteristics Note: This operating sound value (calculated value) is measured at an anechoic room. The actual value is bigger than the calculated value because of the surrounding noise and reverberations. (1)TGMP224B 1. Overall data (dB) Front Rear 53 53 Side right left 51 52 Front 1m Noise measuring conditions:(Semi-) anechoic room Heating based on JIS Measuring position 1.5 m 2. Octave band levels (in front) ● 1-26 ● 50/60Hz AISIN Aisin gas heat pump TGMP280B Note: This operating sound value (calculated value) is measured at an anechoic room. The actual value is bigger than the calculated value because of the surrounding noise and reverberations. 1. Overall data (dB) Front Rear 57 57 Side Right Left 55 56 Noise measuring conditions:(Semi-) anechoic room Front 1m Heating based on JIS Measuring position 1.5 m 2. Octave band levels (in front) ● 1-27 ● 50/60Hz 1 SPECIFICATIONS (3)TGMP355B Overall data (dB) Front Rear 58 58 Note: This operating sound value (calculated value) is measured at an anechoic room. The actual value is bigger than the calculated value because of the surrounding noise and reverberations. Side Right Left 55 56 Front Heating based on JIS 1m Noise measuring conditions:(Semi-) anechoic room Measuring position 1.5 m Octave band levels (in front) ● 1-28 ● 50/60Hz 1 SPECIFICATIONS 1.6 System flow chart 1.6.1 Refrigerant System Diagram (1) Cooling The refrigerant (Freon R407C), after exiting the compressor, first flows through an oil separator and a four-way changeover valve. Next, the refrigerant is introduced into an outdoor heat exchanger, where it is then derived of heat by outside air to change into condensed and liquefied form. The refrigerant liquid is further cooled by the supercooler coil. After this, the refrigerant liquid goes to the indoor unit and is depressurized by the electronic expansion valve within the indoor unit. Thus, the refrigerant is deprived of indoor heat to become gasified for cooling. After that, the refrigerant gas returns to the outdoor unit. In the outdoor unit, the gas returns to the compressor, passing through the four-way valve and the accumulator. Outdoor heat exchanger Outdoor unit Indoor unit Outdoor heat exchanger Cooling Capillary Accumulator Indoor heat exchanger Changeable Compressor Strainer Ball valve Compressor Indoor heat exchanger Oil separator Ball valve Capillary Four-way changeover valve SN1: High pressure sensor SW1: High pressure switch SW2: High pressure switch EV1: Hot gas bypass valve EV2: Oil gas bypass valve 1 EV3: Oil gas bypass valve 2 : Filer dryer : Strainer : Capillary : Check valve : Temperature sensor P1 : High pressure port EEV1: Quantity adjustment valve EEV2: Liquid adjustment valve Strainer Double pipe heat exchanger 1 SPECIFICATIONS (2) Heating The refrigerant (Freon R407C), after exiting the compressor, first flows through an oil separator and a four-way changeover valve. Next, the refrigerant is introduced into an indoor heat exchan ger (indoor unit), where it then releases internal heat to the room and is condensed and liquefied. After this, the refrigerant is depressurized by the electronic expansion valve within the outdoor u nit and by a capillary tube. After flowing through the capillary tube, the refrigerant is introduced i nto an outdoor heat exchanger, where it then absorbs heat and is gasified. Then, after the refrig erant joins with the refrigerant that absorb heat from the outside air and goes through four way c hangeover valve, the refrigerant absorb heat from engine exhaust heat in double pipe heat exchan ger and gasified. The refrigerant returns to the compressor through an accumulator. Outdoor heat exchanger Outdoor unit Indoor unit Outdoor heat exchanger Cooling Capillary Accumulator Indoor heat exchanger Changeable Compressor Strainer Ball valve Compressor Indoor heat exchanger Oil separator Ball valve Capillary Four-way changeover valve SN1: High pressure sensor SW1: High pressure switch SW2: High pressure switch EV1: Hot gas bypass valve EV2: Oil gas bypass valve 1 EV3: Oil gas bypass valve 2 : Filer dryer : Strainer : Capillary : Check valve : Temperature sensor P1 : High pressure port EEV1: Quantity adjustment valve EEV2: Liquid adjustment valve Strainer Double pipe heat exchanger 1 SPECIFICATIONS 1.6.2 Coolant/Fuel/Air System/oil supply Diagram and description Coolant In heating or low-temperature cooling modes, the coolant that has been sent from the coolant pump and heated through the exhaust heat exchanger and the engine flows into the double pipe heat exchanger and heats the refrigerant to contribute to the improvement of heating and evaporating capabilities. In cooling mode, when there is no need for heat to be released through the double-pipe heat exchanger, an increase in the coolant temperature changes over the motor-driven three-way valve to the radiator and returns the coolant to the coolant pump after heat has been released through the radiator. Fuel The fuel gas is passed through a dual-type gas-operated solenoid valve unit, then depressurized to an atmospheric pressure by a gas regulator, and supplied to a gas mixer. The high-pressure section of the fuel line is isolated from the engine room to ensure safety. Intake air and exhaust gas Intake air is passed into the mixer through a silencer and an air cleaner, then mixed with the fuel, and enters the engine cylinders. Exhaust gas releases heat in the exhaust heat exchanger and then the gas itself is released to the atmosphere through the exhaust air pipe. The condensate that has been generated by the release of heat from the exhaust gas is temporarily collected into a drain filter and then released from the unit through a drain hose. ‡ I ‡ L ‡ Q ‡ E ‡ M ‡ M ‡ H ‡ K ‡ G ‡ A ‡ D ‡ P ‡ @ ‡ F ‡ C ‡ B ‡ J ‡ R ‡ N ‡ O Engine pipe Gas mixer Gas regulator Exhaust air heat exchanger Gas electromagnetic valve Air cleaner Intake air silencer Temperature control valve Electric three-way valve Coolant inlet Coolant pump Double pipe heat exchanger Exhaust air Reservoir tank Oil sub-tank Radiator Drain filter Exhaust air drain hose Water temperature sensor AISIN Aisin gas heat pump 2 CONTROL Chapter 2 CONTROL 2.1 System Control Function List 2.1.1 Outdoor unit 2.2.2.Indoor unit 2.2 Remote Control Unit Functions 2.3 DIP Switches for Function Selection 2.4 System Input/Output Specifications 2.4.1 Indoor Unit Input/Output Specifications 2.4.2 Sensor Mounting Positions 2.5 Protection Units 2.5.1 Protection units and Sensor functions 2.5.2 Outdoor unit Input/Output Specifications 2.6 Outdoor Unit Electrical Wiring Diagrams 2.6.1 Outdoor Unit Electrical Wiring Diagram 2.6.2 Indoor Unit Wiring Diagram 2-1 2 CONTROL NOTE 2-2 2.1 System Control Function List - Judgment of antifreezing operation conditions - Detection of indoor unit heat exchanger sensor wire disconnections [Alarm code: E6 (96-?)] - Detection of indoor unit heat exchanger sensor short-circulting [Alarm code: E56 (94-?)] Heat exchanger temperature sensor Fan motor Vane motor operation inhibition (cooling inhibition conditions: Less than –12°C) - Apparent engine speed control - Detection of outside air temperature sensor wire disconnections [Alarm code: E38 (61-0)] - Detection of outside air temperature sensor short-circuiting [Alarm code: E38 (61-1)] Serial communications 200 VAC Indoor unit Room temperature sensor Outside air temperature sensor Float switch Drain pump See “2.3 DIP Switches for Function Selection” to set the jumper wires and DIP switches on the indoor unit board. - Detection of room temperature - Detection of room temperature sensor wire disconnections [Alarm code: E7 (97-?)] - Ambient temperature judgment for system - Detection of indoor drain alarm [Alarm code: E9 (95-?)] Indoor address No. External control terminal CN-Z HA terminal J1 J2 J3 SW1 SW2 SW3 SW4 Indoor circuit board CN-T Fan speed control with heating thermovalve off Louver 4-position setting Louver angle setting (except for TKT) High-ceiling control (for TKT) Outdoor address No. Indoor control section - Information that has been entered from the remote control unit and information that has been detected by sensors are transferred to the outdoor control section. - Based on the information received from the outdoor control section, output signals and display signals are transferred to the terminals of various system components and to the remote control unit respectively. Communi- Remote cations control Power line line 1 2 A B X Y Z Indoor unit to remote control unit 1. Start/stop signal 2. Operation mode (Cooling, heating, blowoff, or dehumidification) 3. Fan speed 4. Direction of air flow 5. User-set temperature 6. Filter sign 7. Ready for heating 8. Centralized control 9. Indoor unit address 10. Alarm code 11.Room temperature 12.Periodic check display Remote control unit to indoor unit 1. Start/stop signal 2. Operation mode (Cooling, heating, blowoff, or dehumidification) 3. Fan speed 4. Direction of air flow 5. User-set temperature 6. Filter reset signal (7. Remote control unit sensor temperature — for remote control unit with sensor) Operations 1. 2. 3. 4. 5. Polarized tri-conductor 200 VAC Coolant temperature sensor (1) (2) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Start/stop signal Operation mode (Cooling, heating, blowoff, or dehumidification) Fan speed Direction of air flow User-set temperature Filter reset signal Defrosting signal Address No. Alarm code Compressor ON Operation test signal Answerback frequency (Hz) Periodic check display * Use the switches only when remote monitoring system is used. Addressing switch Address 1 [Setting Address 1] Factory setting: 49 Manual addressing: 00 to 47 Automatic addressing: 49 Outdoor control section - Based on the information received from each sensor and the indoor control section, output signals are sent to various system components. - Transfar the information detected by each sensor to the indoor control section. Starter coil terminals - Detection of starter malfunction [Alarm code: E83 (60-2)] Pickup coil - Detection of engine speed - Detection of overspeed error [Alarm code: E82 (82-0, 1)] - Detection of engine starting speed error [Alarm code: E83 (74-1)] 200 VAC Oil pressure switch 5. Winterized type setting (ON: Winterized type, OFF: Normal type) 6. Optional setting for coolant heater (ON: With heater, OFF: Without heater) 7. Silent mode setting (ON: Silent mode. OFF: Normal mode) 8. — 9. Optional setting for deodorization (ON: Deodorization, OFF: Normal mode) 10. — Refrigerant high-pressure switch - Detection of refrigerant high-pressure alarm [Alarm code: E40 (86-0)] - Detection of wire disconnections [Alarm code: E40 (76-0)] Refrigerant low-pressure sensor - Detection of refrigerant low-pressure alarm [Alarm code: E57 (88-0)] - Detection of wire disconnections [Alarm code: E57 (88-2)] - No refrigerant [Alarm code: E57 (88-5)] 200 VAC Throttle valve Four-way changeover valve 12 VDC 12 VDC Stepping motor Compressor clutch (L, R) 200 VAC Accumulator inlet temperature sensor 200 VAC - Hot-gas bypass valve - Oil bypass valve Igniter Main - Control of refrigerant high-pressure, control of outdoor fan speed. - Refrigerant high-pressure sensor alarm [Alarm code: E89 (73-0, 1)] Starter Compressor intake temperature sensor Sub Refrigerant high-pressure sensor 12 VDC 12 VDC signal 12 VDC Reset signal Heat exchanger fan motor 12 VDC - Oil pressure alarm [Alarm code: E81 (81-0)] - Wire disconnection alarm [Alarm code: E86 (71-0)] 1. Periodic check display (ON: Yes, OFF: No) 2 Periodic check display time (ON: 6000 hrs, OFF: 10000 hrs) 3. 4. Gas type selection X Y Z See “2.3 DIP Switches for Function Selection” to set the function switches and jumper wires on the remote control unit board. Remote control unit master/sub addressing 200 VAC AC/DC converter 6. 7. 8. (8. Remote control unit 200 VAC Remote monitoring addressing switch - Engine warm-up completion judgment - Detection of coolant overheating avoidance operation - Detection of coolant temperature alarm [Alarm code: E80 (80-0)] - Detection of wire disconnections [Alarm code: E87 (70-0)] - Detection of short-circuiting [Alarm code: E80 (80-1)] - Detection of engine coolant shortage [Alarm code: E80 (80-2)] - Control of outdoor heat exchanger fan speed - Detection of wire disconnections [Alarm code: E53 (53-0)] - Detection of short-circuiting [Alarm code: E53 (53-2)] - Detection of abnormal temperature increase [Alarm code: E89 (87-0)] (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Start/stop signal Operation mode (Cooling, heating, blowoff, or dehumidification) Fan speed Direction of air flow User-set temperature Filter sign Filter reset signal Address No. Alarm code Compressor ON/OFF Indoor temperature Indoor heat exchanger temperature Request frequency (Hz) Black Indoor unit to outdoor unit Red Unpolarized dubal-conductor - Judgment of antifreezing operation conditions during heating - Detection of gas pipe temperature sensor wire disconnections [Alarm code: E55 (64-0)] - Detection of gas pipe temperature sensor short-circuiting [Alarm code: E55 (64-1)] Outdoor unit to indoor unit White Serial communications Gas pipe gas temperature sensor Start/stop signal Operation mode Fan speed Auto-swing User-set room temperature (User-set time) Timer mode Filter reset signal Check Filter auto-lifting — for L-type remote control unit) 200 VAC - Detection of wire disconnections [Alarm code: E54 (63-0)] - Detection of short-circuiting [Alarm code: E54 (63-1)] Coolant pump Discharge temperature sensor Outdoor unit heat exchanger liquid sensor 2-3, 4 - Answerback frequency calculation - Detection of outdoor unit heat exchanger liquid sensor wire disconnections [Alarm code: E89 (65-0)] - Detection of outdoor unit heat exchanger liquid sensor short-circuiting [Error code: E89 (65-2)] AISIN Ventilation fan 12 VDC - Gas-operated solenoid valve - Liquid flow regulation valve - Motor-driven three-way valve - Fuel gas regulation valve - Capacity regulation valve - Detection of discharge temperature increase avoidance operation - Detection of discharge temperature alarm [Alarm code: E36 (91-0)] - Detection of wire disconnections [Alarm code: E39 (78-0, 1)] - Detection of short-circuiting [Alarm code: E36 (91-2, 3)] AI SIN Aisin gas heat pump System block chart Maintenance equipment Remote Controller Communication Description 1.Centerized control (Center/ remote) 2.Operation mode 3.Fan airflow rate 4.Auto-swing 5.Use-set room temperature 6.Timer mode 7. Intake temperature 8. Filter sign 9. Ready for heating 10.Error code 11.Unit number 12.Operation and check LED 13.Indoor heat exchanger temperature Trial operation in cooling 14. Periodic inspection 1.Start / Stop 2.Operation mode 3.Fan airflow rate 4.Auto-swing 5.Indoor temperature setting (Use-set time 6.Timer mode 7.Filter reset signal 8.Check 9. Filter automatic up-down (Only with L type remote controller) Remote controller → Indoor 1. Start / Stop 2. Operation mode (Dehumidification, cooling, ventilating, heating) 3. Fan air flow rate 4. Direction of air flow 5. User-set temperature 6. Filter reset (7 Remote controller sensor temperature)*Using remote controller with sensor Power supply AC 200 V (Three-phase or single phase) Communication 1. Remote controller sensor 2. Address switch Description of communication between Remote controllers – Indoor unit Indoor→Remote controller 1. Start / Stop 2. Operation mode (Dehumidification, cooling, ventilating, heating) 3. Fan air flow rate 4. Direction of air flow 5. User-set temperature 6. Filter sign 7. Ready for heating 8. Centralized control 9. Indoor unit address number 10. Error code 11. Room temperature 12. Periodic inspection display Power supply AC 200V (Single phase) Operation Input signal Indoor control section Outdoor control section Operation time display Error monitor (red) Communication Input signal Input signal Output 1. 1. Heat exchanger fan motor 2. Vane motor 3. Drain motor 4. HA terminal 5. Outdoor control terminal 6. Electronic expansion valve Indoor temperature sensor 2. Indoor heat exchanger temperature sensor 3. Float switch 4. Limit switch In position of the vane 5. HA terminal 6. Outdoor control terminal 7. Dip switch for change of control 8. Indoor address switch 9. Outdoor address switch Output (DC12V) Description of communication between indoor and remote controller Outdoor → Indoor 1. Start / Stop Signal 2. Operation mode (Dehumidification, cooling, ventilating, heating) 3. Fan air flow rate 4. Direction of air flow 5. User-set temperature 6. Filter reset 7. Defrosting signal 8. Address no. 9. Error code 10. Starting Compressor 11. Trial operation 12.Answer frequency 13. Periodic inspection display Indoor → outdoor 1. Start / Stop Signal 2. Operation mode (Dehumidification, cooling, ventilating, heating) 3. Fan air flow rate 4. Direction of air flow 6. User-set temperature 6. Filter sign 7. Filter reset 8. Address no. 9. Error code 10. Compressor ON / OFF 11. Indoor temperature 12. Indoor heat exchanger temperature 13. Request frequency Output (AC200V) Output (AC200V) DC12V Signal (DC12V) 2-5,6 Sensor 1. High pressure switch 2. Low pressure switch 3. Engine oil pressure switch 4. Water temperature sensor 5. Outdoors air temperature sensor 6. Discharge temperature sensor (1-4) 7. Engine room temperature sensor 8. Accumulator inlet temperature sensor (1,2) 9. Engine RPM sensor 10. High pressure sensor 11. Heat exchanger liquid temperature sensor 12. Intake temperature sensor 13. Accumulator inlet temperature sensor 14. Discharge air temperature sensor (Option) 1. 2. 3. 4. Switch on control board Dip switch for changing control Outdoor address switch Switch for maintenance Address switch for long-distance monitor 1. 2. 3. 4. 5. 6. 7. Compressor clutch (R-L) Throttle valve Gas electromagnetic valve (1,2) Liquid flowing capacity adjustment valve Electrical three-way valve Fuel gas adjustment valve Capacity adjustment valve 1. Electric motor for ventilator 2 2. Coolant pump 3. Four-way changeover valve 4. Ventilation fan 5. Hot gas bypass valve 6. Oil return valve (1 to 4) 7. Discharge drain heater (only for cold district specification 8.Compressor heater (only for cold district specification) 9. Coolant heater (Option) AC/DC changeover equipment (Transformer, Diode) AISIN Aisin gas heat pump 2.2 Remote Control Unit Functions (The following view shows the remote control unit with its cover opend.) Filter sign When this display appears, clean the air filter. Operation mode display Shows the selected operation mode. Periodic check display When this display appears, perform periodic check of the outdoor unit. Heating ready status display REMOTE display Weak air blowoff or stop status is displayed when the thermovalve is turned off or when defrosting or heating is started up. Indicates that the air-conditioning system is being controlled from the remote control unit. (This display appears, even when the system is not in use.) Operation/check indicator lamp CENTER display Operating: Green on. Alarm: Red blinking. Indicates that the air-conditioning system is being controlled from an optional center remote control unit. OPERATE/STOP switch Timer operation display Starts and stops the air-conditioning system. Press the switch once to select OPERATE. Press again to select STOP. Shows details of timer operation. (This display appears, even when the air-conditioning system is not in use.) Intake air temperature display Shows the intake air temperature. SET TEMP display This display may differ from the value indicated on an actual instrument such as a thermometer. This state, however, is not abnormal. Shows the user-set temperature. Fan speed display Shows the user-set fan speed. Auto-swing display Shows swing louver status. Filter auto-lifting control switch Moves the filter (intake grill) vertically. MODE switch Allows operation mode selection. Cover FAN SPEED switch CHECK switch Allows the selection of a fan air flow rate. Use the switch to service the system. AUTO SWING switch TIMER switch Starts and stops the swing louver automatically. Use the switch to specify details of timer operation. SET switch TEMP/TIME/INTAKE GRILL switch Use the switch to set the timer clock. Allows room temperature setting, timer clock setting, and intake grill vertical movement. 2-7 2 CONTROL 2.3 DIP Switches for Function Selection (1) Indoor unit – Jumper wire connection No. J1 Function Setting Other than TKT Louver angle selection (Indoor unit types only) TKT High-ceiling control J2 Louver control J3 Fan speed with heating thermovalve off J4 Filter sign J5 Operation control J6 Expansion valve control Description Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) Connected (ON) Not connected (OFF) TKTW, TKTC TKTS, TKE, TKK Normal High-ceiling control Intermittent operation Stop at any position Weak air blowoff Stop On after 600 hours Invalid Normal CN-T input ON: Operation enabled. OFF: Operation inhibited. Automatically identified New angle fixed – DIP switch assembly SW5 setting No. Function Setting SW5-1 CN-1 remote start/stop input SW5-2 Heating temperature correction SW5-3 Drain pump SW5-4 Set to OFF. Description ON OFF ON OFF ON OFF Inversion input Edge input –3°C Normal Forced operation Normal – DIP switch assembly SW6 setting P22 P28 P36 P45 P56 P71 P80.90 P112 P140 P160 P224 P280 SW6-1 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON SW6-2 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON SW6-3 OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF SW6-4 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON Note: Type select switch assembly SW6 is set to the appropriate status (default) according to the particular capacity of the indoor unit(s). Do not disturb this setting. – DIP switch assembly SW9 setting No. Function Setting ON SW9-1 SW9-2 Auto-lifting stroke (downward) 2 1 OFF 2-8 TKT Other than TKT ON 400 (cm) 200/ — (cm) OFF 160 (cm) 160/200 (cm) ON 200 (cm) 130/160 (cm) OFF 130 (cm) — /130 (cm) AISIN Aisin gas heat pump (2) Remote control unit Remove the upper casing from the remote control unit and set the switches. : Default To the indoor unit Selector switches (on side of board) Switches Upper casing Setting Function Cool Cooling only (*4) Heat Heat pump Remote control sensor SW2 Yes Valid (Main remote control unit only) No Invalid (Indoor unit sensor valid) Power interruption compensation SW3 Yes Valid No Invalid (Initialized on power interruption) Remote control SW4 (*3) Sub Sub remote control (Main/sub remote control) Main Main remote control Type selection SW1 Heat-sensitive section of sensor Jumper wire connection Swing jumper J4 (*2) Timer function jumper J3 Fan speed select jumper J2 (*1) Intake temperature display jumper J1 Not connected Display off Connected Display on Not connected Connected Not connected Connected Invalid Valid 2-speed type Very high ↔ Low 3-speed type Very high ↔ High ↔ Low Not connected Display off Connected Display on *1: Use the table below to set fan speed select jumper J2. J2 Jumper Setting Not connected (OFF) Connected (ON) Type of Indoor Unit TKT, TKTC, TKTW, TKTS, TKR, TKE (other than P280) TKK, TKF, TKFL, TKFU TKU, TKUM, TKUF, TKES, TKFP, TKFD, TKE (P280) *2: Use the table below to set swing display jumper J4. J4 Jumper Setting Type of Indoor Unit Not connected (OFF) TKR, TKU, TKUM, TKUF, TKES, TKFL, TKFU,TKFP,TKFD Connected (ON) TKT, TKTC, TKTW, TKTS, TKE, TKK,TKF *3: The check reset, filter sign reset, and auto-lifting control functions can be controlled only with the main remote control unit. *4: The indoor unit TKUF is used only for cooling. Set SW1 to Cool. Note: To operate the system in cooling test mode, first press the OPERATE switch and select cooling mode. Next, press the SET switch while holding down the “TEMP ∇” switch. Thirty-minute forced cooling will be initiated. Press the STOP switch to abort the cooling operation. 2-9 2 CONTROL Function switches on the outdoor unit control circuit board Remote monitoring addressing switch SW5 SW6 SW Use the switches only when remote monitoring system is used. Address switch SW1 SW2 Setting Address 1 Factory setting: 49 Manual addressing 00 to 47 Automatic addressing 49 (Setting operation detection Address 1 Do not turn on in operation SW 1: Periodic check display Periodic check display on ON Periodic check display off OFF 2: Periodic check display time 6000 hours ON 10000 hours OFF 3: 4: Setting gas type 5: Cold district specifications Cold district specifications valid ON Normal specifications valid OFF 6: Engine oil pan heater (Optional setting) with Oil pan heater ON Normal mode on OFF 7: Full-time silent mode ON Full-time silent mode on Normal mode on OFF 9. Optional setting for deodorization ON Deodorization OFF Normal mode 12A A-class Gas 13A 1 2 propane type SW7-4 OFF OFF ON SW7-3 OFF ON ON SW7-2 OFF OFF OFF 3 Include 12A 12A 40MJ/m N or more 3 12A less than 40MJ/m N) 3 Propane Air (63MJ/m N) 2-10 AISIN Aisin gas heat pump 2.4 System Input/Output Specifications 2. 4. 1. Indoor Unit Input/Output Specifications No. 1 Name Indoor temperature sensor Electrical Component Specs. Functions (1) Temperature control (2) Cooling/heating changeover during automatic operation Connector No. Thermister R25 = 5 kΩ B = 3950 k CNH, pins 1 and 2 Thermister R25 = 5 kΩ B = 3950 k CNH, pins 3 and 4 (3) Indoor fan speed control during dehumidification Indoor heat exchanger sensor (1) Control of hot-starting 3 Float switch (1) Detection of drainage alarm Normal: ON Abnormal: OFF OFF: 200 VAC ON: 10 VAC or less FASTON 9-5 4 Vane position (Limit switch) (1) Cycle time self-learning and control by power feeding to motor immediately after power-on Voltage applied: 5 VDC Rated current: 5 mA CNS 2 (2) Antifreezing control (3) Display of remotely controlled heat exchanger temperature in operation test mode (2) Louver horizontal position detection 5 6 Rotary switches HA terminals (1) Indoor unit addressing with blue SW1 and SW2 Manual addressing: 0 to 47 Automatic addressing: 49 SW1: Address (10’s place) SW2: Address (1’s place) (2) Outdoor unit addressing with green SW3 and SW4 Manual addressing: 0 to 47 Automatic addressing: 49 SW3: Address (10’s place) SW4: Address (1’s place) (1) OPERATE/STOP instruction Based on Japanese Electric CNZ, pins Machine Industrial Standard 1 and 2 (HA) JEM1427-1987 – The operation control signal waveform is shown below. – This signal is used for the gas heat pump to reverse the OPERATE/STOP signal level. Tp Ti Tp: Pulse “on” time (200 - 300 msec) Ti: Pulse interval (200 msec or more) (2) Operation monitoring signal – Gas heat pump on/off status output signal (Static signal) Operation control signal Operation Tr Tr Operation monitoring signal Tr: Response time (300 msec or less) 2-11 CNZ, pins 3 and 4 (HA) 2 CONTROL No. 7 Name External control terminals Electrical Component Specs. Functions (1) Operation monitoring output On when remote control unit is on (2) Heating mode monitoring output On during heating (except for defrosting) Can be driven at 12 VDC/ 75 mA with the OMRON LY2F relay. Connector No. CNT, pins 1 and 2 CNT, pins 1 and 3 (3) Compressor monitoring output On when compressor is on CNT, pins 1 and 4 (4) Alarm monitoring output On in case of alarm CNT, pins 1 and 5 (5) OPERATE/STOP instruction CNT, pins 1 and 6 ON Operating Stopped OFF Operation starts and stops with the rising and falling edges, respectively, of the signal. Note: When pin 1 of DIP SW5 is on, the OPERATE/STOP signal level is reversed at the rising edge of the signal shown above. 8 9 Heat exchanger fan (Low) Fan speed can be changed by tap changeover. Heat exchanger fan (High) 200 VAC (1) Specification of fan speed from remote control unit FASTON tab (2) Control of hot-starting 5 and 8 (3) Dehumidification FASTON tab Note: TKU is of the two-speed type (“High” and “Very high” select lines are connected outside the circuit board). TKF and TKFD are of the single-speed type. Heat exchanger fan (Very high) (4) Heating thermovalve-off intermittent operation (without J-3) Vane motor The vane motor controls the louver. 5 and 7 FASTON tab 5 and 6 200 VAC (1) Specification of air flow direction from remote control unit (2) Control of hot-starting FASTON tab 3 and 5 The stopping position of the louver differs according to the type of indoor unit used. J-1 connected: TKTS or TKE type J-1 not connected: Other types 10 Drain pump (1) On during cooling or dehumidification when compressor is on. 200 VAC (2) On when float switch is off. 4 and 5 (3) Turned off two minutes after float switch-on. 11 Fan controller FASTON tab (1) The fan speed from the TKU type of indoor unit can be continuously adjusted with the appropriate control. 2-12 200 VAC AISIN Aisin gas heat pump 2.4.2 Outdoor Unit Input/Output Specifications No. Name Electrical Component Specs. Functions Connector No. 1 Refrigerant high-pressure switch (1) Stoppage judgment associated with unusually high pressure (2) Detection of refrigerant high-pressure switch wire disconnections Contact point switch (12 VDC) Normal: ON CN8, pins 3 (black) and 4 (black) 2 Heat exchanger liquid temperature sensor (1) Answer frequency calculation (correction of supercooling) (2) Wire disconnection/short-circuiting detection for heat exchanger liquid temperature sensor Thermister R0 = 15 kΩ B = 3450 k CN6, pins 1 (white) and 2 (white) 3 Heat exchanger gas temperature sensor (1) Frosting detection during heating (2) Refrigerant high-pressure error avoidance control during cooling (3) Wire disconnection/short-circuiting detection for heat exchanger gas temperature sensor Thermister R0 = 15 kΩ B = 3450 k CN6, pins 9 (white) and 10 (white) 4 Outside air temperature sensor (1) System operation inhibition ambient temperature judgment (Inhibition of operation: Below –12°C during cooling) (2) Control of oil returning valve (3) Wire disconnection/short-circuiting detection for outside air temperature sensor (4) Control of outdoor fan quantity Thermister R0 = 15 kΩ B = 3450 k CN6, pins 15 (white) and 16 (white) 5 Compressor discharge temperature sensor (1) Compressor discharge temperature alarm judgment (2) Compressor discharge temperature alarm avoidance control (3) Wire disconnection/short-circuiting detection for compressor discharge temperature sensor Thermister R0 = 15 kΩ B = 4095 k R: CN6, pins 7 and 8 Compressor intake temperature sensor (1) Wire disconnection/short-circuiting detection for compressor intake temperature sensor (2) Oil returning error detection Thermister R0 = 15 kΩ B = 3450 k CN6, pins 11 (white) and 12 (white) 7 Accumulator inlet temperature sensor (1) Wire disconnection/short-circuiting detection for accumulator inlet temperature sensor (2) Oil returning error detection Thermister R0 = 15 kΩ B = 3450 k CN6, pins 3 (white) and 4 (white) 8 Engine coolant temperature sensor (1) (2) (3) (4) Engine coolant alarm judgment Engine warm-up completion judgment Engine coolant alarm avoidance control Engine coolant no-load operation preventive control (5) Wire disconnection/short-circuiting detection for engine coolant temperature sensor (6) Outdoor fan speed control Thermister R100 = 3.3 kΩ B0/100 = 3970 k CN7, pins 9 (black) and 12 (white) 9 High-pressure sensor (1) Refrigerant high-pressure control (for maintaining high pressure in heating mode) (2) Refrigerant high-pressure error avoidance control (3) Outdoor fan speed control (4) Answer frequency calculation (correction of supercooling) 5 ± 0.5 VDC CN7, pins 8 (red) and 4 (black) 10 Low-pressure switch (1) Low-pressure abnormality stop judgment Contact point switch (12 VDC) Normal: ON CN8, pins 1 (black) and 2 (black) 6 L: CN6, pins 5 and 6 (3) Compressor intake temperature alarm avoidance control (2) Detection of refrigerant low-pressure switch wire disconnections 2-13 2 CONTROL No. Name Electrical Component Specs. Functions 11 Engine revolutions (1) Detection of engine revolutions signal (crank angle sensor) 12 Engine oil pressure switch (1) Oil pressure abnormality judgment (2) Detection of engine oil pressure switch wire disconnections 13 Starter malfunction detection signal (1) Starter malfunction detection (2) Starter trouble and wire disconnection detection 14 Compressor clutches (L, R) (1) Turns on in accordance with a request frequency instruction from the indoor unit, but only when the inhibition timer is off. ON: 1 VDC or less OFF: 11 to 13 VDC Connector No. CN8, pins 17 (brown) and 18 (yellow) CN23, pin 1 12 VDC/4 A R: CN12, pin 2 L: CN12, pin 1 (2) Control of refrigerant flow rate (quantitative control of units to be operated) 15 Starting motor (1) Support for autonomous engine start 11 to 19 VDC Motor plus terminal to ground 16 Igniter (1) Controls the ignition timing of the three-cylinder engine ignition coils. 12 VDC IGN-H, C 17 Stepping motor for (1) Control of engine revolutions engine control Note: For details see “Stepping Motor Control”. Structure: 4-phase PM Excitation: 1-2 phase Single-step angle: 0.15° CN11 18 Coolant pump (1) Circulation of engine coolant 200 VAC CN13, pins 5 (black) and 9 (white) 19 Ventilation fan (1) Internal ventilation of engine room 200 VAC CN14, pins 3 (white) and 10 (black) 20 Four-way changeover valve (1) On during heating 200 VAC Note: This valve is activated either 60 sec after turning on the both compressors or if a differential pressure of 0.2 MP between the high-pressure and low-pressure circuits persists for 10 sec in succession. The valve is switched when an operation mode different from the previous mode is selected or when power is turned on. CN15, pins 2 (black) and 11 (black) 21 Gas electromagnetic valve 1 (1) Supply and shutoff of fuel gas to outdoor unit CN7, pins 19 (white) and 20 (white) 22 Gas electromagnetic valve 2 10 to 16 VDC (Full-wave rectification of 14 VAC) 23 Heat exchanger fan motor 1 200 VAC/100 W CN13, pins 2 and 7 24 Heat exchanger fan motor 2 (1) Four-level control (H, M, L, UL) when the thermovalve is open during cooling (2) Single-level control (H) when the thermovalve is open during heating (3) Stop when defrosting in heating mode is necessary or the thermovalve is closed (1) Operates in oil returning valve control mode. The amount of oil return within the required range is obtained from OCR calculation results. 200 VAC/7 W (1) Controls the liquid flow valve to stabilize the compressor intake temperature and discharge temperature. Structure: 4-phase PM Excitation: 2 phase High Low 25 Oil returning valve 1 26 Oil returning valve 2 27 Liquid flow regulating valve (2) Defrosting operation during heating 2-14 CN7, pins 17 (black) and 18 (black) CN13, pins 3 and 4 CN13, pins 3 and 8 CN15, pins 9 and 17 CN15, pins 8 and 16 CN10-1 to 7 AISIN Aisin gas heat pump 2.4 2.4.1 Protection Units Protection Units and Sensor Functions Protection Unit Detector Check Display Error Item Control Connector Starter malfunction detection signal On the outdoor unit board CN23-1 Starter malfunction Engine speed signal On the outdoor unit board CN5 Engine speed too high Pickup coil E83 Insufficiency of starting engine speed Engine speed control error Engine speed hunting error Coolant temperature sensor On the outdoor unit board CN7-9, 12 Remote Maintenance Control Unit Board E82 E83 82-1 74-1 74-4 Engine starting failure E84 84-0 Engine stop E85 75-0 Engine micon communication error — 84-3 Engine program input malfunction — 84-4 Engine coolant temperature sensor short-circuiting 80-0 E80 80-1 80-2 Engine coolant temperature sensor wire disconnections E87 70-0 Engine oil pressure error E81 81-0 Engine oil pressure switch wire disconnections E86 71-0 Oil pressure switch On the outdoor unit board CN8-17, 18 Refrigerant high-pressure switch On the outdoor unit board CN8-3, 4 High-pressure sensor On the outdoor unit board CN7-3, 4 High-pressure sensor error Refrigerant low-pressure switch On the outdoor unit board CN8-1, 2 Refrigerant low-pressure error Compressor discharge temperature sensor R/L On the outdoor unit board R: CN6-7, 8 L: CN6-5, 6 Refrigerant high-pressure switch wire disconnections E40 Refrigerant high-pressure error 73-0 E89 Refrigerant low-pressure switch wire disconnections 76-0 86-0 73-1 88-0 E57 88-2 No refrigerant 88-5 Compressor discharge temperature too high 91-0 Compressor discharge temperature sensor short-circuiting (R) E36 Compressor discharge temperature sensor short-circuiting (L) Compressor discharge temperature sensor wire disconnections (R) Compressor discharge temperature sensor wire disconnections (L) On the outdoor unit board CN6-11,12 82-0 74-6 No engine coolant Compressor intake temperature sensor 60-0 — Engine coolant temperature too high Red LED Blinking Compressor intake temperature sensor wire disconnections Compressor intake temperature sensor short-circuiting Compressor intake temperature too high 2-15 91-2 91-3 78-0 E39 78-1 53-0 E53 53-2 E89 87-0 Continuous 2 CONTROL Protection Unit Check Display Detector Control Connector Error Item Accumulator inlet temperature sensor On the outdoor unit board CN6-3, 4 Accumulator inlet temperature sensor wire disconnections Engine room temperature sensor On the outdoor unit board CN6-13, 14 Exaust temperature sensor (option) On the outdoor unit board CN7-13, 14 Outside air temperature sensor On the outdoor unit board CN6-15, 16 Outdoor heat exchanger liquid temperature sensor On the outdoor unit board CN6-1, 2 Gas pipe temperature sensor On the outdoor unit board CN6-9, 10 Outdoor unit addressing switch On the outdoor unit board SW1, 2 Communication cable On the outdoor unit board CN26-1, 2 Accumulator inlet temperature sensor short-circuiting Engine room temperature sensor short-circuiting Inside the outdoor unit board Indoor unit addressing switch On the indoor unit board SW1, 2, Remote control unit wire On the indoor unit board CnB Communication cable On the indoor unit board CnK Indoor heat exchanger sensor On the indoor unit board CNH 3-4 72-0 E52 Outside air temperature sensor short-circuiting Outdoor heat exchanger liquid temperature sensor wire disconnections Outdoor heat exchanger liquid temperature sensor short-circuiting Gas pipe temperature sensor wire disconnections Gas pipe temperature sensor short-circuiting 75-1 72-6 E58 Outside air temperature sensor wire disconnections Continuous 63-1 Exhaust temperature sensor wire disconnections Exhaust air error 47-0 61-0 E38 61-1 65-0 E89 65-2 64-0 E55 64-1 Gas electromagnetic valve output error E83 74-7 Outdoor unit address number overlapping E31 31-0 Outdoor unit address number setting error — 4-0 Indoor-outdoor communications error — 5-0 Power supply connection error — 41-1 — 41-2 E34 41-1 Communication impossible — 50-0 Local send data not readable — 50-0 No indoor unit connected — 3-0 Indoor unit address number overlapping E2 2-0 Indoor unit address number setting error E12 — Too many indoor units are connected E43 43-0 Mode unmatch E61 93-? Indoor units unmatch E85 44-? Communications error between remote control unit and indoor unit E1 1-0 Remote controller intake temperature sensor disconnection E28 43-0 Pairing error E3 — Communications error between indoor unit and outdoor unit E5 — EEPROM error — 40-0 Indoor heat exchanger sensor wire disconnections E6 96-? Indoor heat exchanger sensor short-circuiting E56 94-? 2-16 Red LED Blinking 63-0 E54 Engine room temperature sensor wire disconnections Less phase error Outdoor unit board Remote Maintenance Control Unit Board AISIN Aisin gas heat pump Protection Unit Detector Control Connector Check Display Error Item Indoor intake sensor On the indoor unit board CNH 1-2 Indoor intake sensor wire disconnections Float switch On the indoor unit board Cnl Indoor unit drain error 2-17 Remote Maintenance Control Unit Board E7 97-? E9 95-? Red LED Blinking Continuous 2 CONTROL 2.4.2 Sensor Mounting Positions Coolant sensor Discharge temperature sensor (L) Engine oil pressure switch Discharge temperature sensor (R) 2-18 AISIN Aisin gas heat pump Intake temperature sensor Low-pressure switch Accumulator inlet temperature sensor Gas pipe temperature sensor Heat exchanger temperature sensor Engine room temperature sensor (mounted on the top plate) Outside temperature sensor High-pressure sensor High-pressure switch 2-19 Box ger room Heat FueL exchan Control box Engine room 2.6. Outdoor unit electrical wiring diagram 2.6.1 Outdoor unit electrical wiring diagram 4PV AIN BV C/P FV C/P L C/P R C/P S C/P TL C/P TR E/G R EFAN EV EWV FUEL GAS HLSW IG1 IG2 IG3 LLSW OLP OVB1 OVB2 PSH STR STM TB1 TB2 THL WB WP WT C/P H DH E/G E E/G WH C1, C2 CS D1, 2, 3 DB ELB FG FU1, 2,3 IGN R1, 2, R3 SUB-PCB TR1 TR2 FM1 FM2 THO GV1 GV2 4-way changeover valve Accumulator inlet temperature sensor Hot gas bypass valve Quantity adjustment valve Compressor clutch L Compressor clutch R Intake temperature sensor Discharge temperature sensor L Discharge temperature sensor R Engine room temperature sensor Ventilation fan Liquid flow adjustment valve Three-way electric valve Fuel gas adjustment valve Gas pipe temperature sensor High pressure switch Ignition coil 1 Ignition coil 2 Ignition coil 3 Low-pressure switch Engine oil pressure switch Oil return valve 1 Oil return valve 2 High pressure sensor Starter Throttle valve Terminal block 1 (for power supply) Terminal block 2 (for communication) Heat exchanger liquid temperature sensor Engine revolution sensor Coolant pump Coolant sensor Compressor heater 1 -4 (only for cold district spec.) Exhaust air drain heater (only for cold district spec.) Exhaust air temperature sensor (option) Engine oil pan heater (option) Condenser for ventilator 1, 2, Electrolysis Condenser Diode 1,2,3 Diode bridge Electrical leakage breaker Frame ground Fuse 1, 2, 3 Digital Igniter (controller) Relay 1, 2 Starter relay Sub-circuit base board Transformer for Starter Transformer for circuit board Electric equipment for ventilator 1 Electric equipment for ventilator 2 Outside temperature sensor Gas electromagnetic valve 1 Gas electromagnetic valve 2 (Only Cold district spec.) P R WR Y Br O Bl W R Y Br O Bl Y W O Bl Bk Br G R Y Br R (Option.) R WW R R Br Br WBk WBk BlBl C o n t r o l W YWO R Bl R W R Y Br O Bl Bk R Bk W Heat ex. Room THO (Option.) Br RR P P W Fuel box Bl Y RW R O Y WBk BlBl WW RWBk BkBk R YY WW WW WW WW WW WW WW WW b o a r d Y Y Bl Bl Bk W W G ROY R W Bk C o n t r o l R Bk W Br W Br b o x (Single phase) (Three phase) E n g i n e r o o m Note1: The setting in the diagram indicates stopping state. Note 2: No color connector is natural Grounding Heat ex. Room 2-20,21 To indoor unit To Long distance surveillance Outdoor 2 CONTROL 2-22 1 For single-phase For 3-phase Option Symbol SW6 SW9-1, 2 J1 J2 J3 J4 J5 TrI Val LED-R LED-G F CnA to Z XR1 XR2 XR3 XR4 XR5 H 52H 26 Tf TB < mark Red Brown Yellow Brown Blue Orange Brown Orange Blue Blue Orange Orange White White Brown Gray Gray White White White Blue Blue White White Red Red Blue Motor Description Wireless interface Operation indicator Check/Timer indicator (yellow) Backup switch *L White White Black White (Signal) Connection lines between indoor units (Power) White Red 2-23 Black White Red Red Red Blue Blue Black White Red Panel Red Black White *L *S Option Gray Orange Red Yellow Black Remote control unit Black Black Black Black Black Black Black Black Black Black Gray Orange Red Yellow Black For lifting stroke of 2 m For wireless auto-lifting panel Normal Check Checker Blue Red Blue Red Receiver 4m Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. Remote control 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and unit B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 9. Use the table below to set the intake grill 6. Do not route the remote control lines in parallel with auto-lifting stroke switches (located on the other power lines. Use shielded wires if parallel routing control board of the main unit). is absolutely necessary. 7. The wiring marked “*S” in this diagram is actually not SW9-1 OFF OFF ON ON provided for a panel without an auto-swinging function. SW9-2 OFF ON OFF ON 8. The wiring marked “*L” in this diagram is actually Lifting Stroke 1.3 1.6 2.0 4.0 provided only for auto-lifting panel specifications. Symbol I/F LED1 LED2 SW Orange Motor Brown Description Heat pump type selection Intake grill auto-lifting stroke setting Control selection for high-ceiling-suspended LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Bimetal switch for H Temperature fuse for H Terminal block (marked {) FASTON terminal PCB Red Yellow Blue Yellow Black Yellow Orange Orange Yellow Pink Blue Blue Brown [Description of symbols] Symbol Description FM1 Motor for blowoff 49F1 Internal thermovalve for FM1 CF1 Capacitor for FM1 DM Drain motor FS Float switch LM Louver motor LS Louver switch SM Stepping motor (for electronic expansion valve) Motors 1, 2 For auto-lifting (for auto-lifiting panel) PS Panel switch X1 to 8 Auxiliary relays ThI-A Intake air sensor ThI-R Heat exchange sensor Thc Thermister accompanying the remote control unit SW1 Unit No. (10’s place) SW2 Unit No. (1’s place) SW3 Outdoor unit No. (10’s place) SW4 Outdoor unit No. (1’s place) SW5-1 ON: Operation input Reversing Invalid Operation Stop OFF: Operation input SW5-2 ON: Temperature setting +3°C OFF: Normal SW5-3 ON: Drain motor ON OFF: Drain motor OFF Blue Blue Red White Red White 2.4.3 To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White AISIN Aisin gas heat pump Indoor Unit Wiring Diagram Ceiling cassette type (4-way blowoff) TKT TKTP28, 36, 45, 56, 71, 80, 90, 112, 140, 160M5, 71, 140S5 Red Blue Yellow Black Blue Black Brown Yellow Brown Red White Red White White White 2-24 *2 White White F CnA to Z XR1 XR2 XR3 XR4 XR5 H 52H 26 Tf TB < mark mark White White Fuse Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Bimetal switch for H Temperature fuse for H Terminal block (marked {) FASTON terminal Closed-end splicer Description The circuit marked "*2" above is actually not wired for a panel without an auto-lifting function. Symbol White SW6 SW9-1, 2 J1 J2 J3 J4 J5 J6 TrI Val LED-R LED-G Red Yellow White SW5-3 Blue SW5-2 Brown Blue Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Louver motor Louver switch Stepping motor (for electronic expansion valve) For auto-lifting (for auto-lifting panel) Panel switch Auxiliary relays Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) Brown Blue Description ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Intake grill auto-lifting stroke setting Control selection for high-ceiling-suspended LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Brown White Symbol SW5-1 Red Blue Description Orange Symbol FM1 49F1 CF1 DM FS LM LS SM Motors 1, 2 PS X1 to 8 ThI-A ThI-R Thc SW1 SW2 SW3 SW4 Orange Motor Brown (Option) Blue Motor Orange Brown [Description of symbols] PCB Orange Orange Orange Yellow Pink Red White Gray Red Brown Yellow Orange Orange White Blue Blue Blue Blue Red White Red White Red Orange White Red Single-phase Connection lines (Signal) between indoor (Power) untis To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz Red White Check Black Orange Red Yellow Black Gray White *1 Option Black Black White Red *2 Remote control unit Black White Black Red Blue Blue The circuit marked "*1" above is actually not provided for a panel without an auto-swinging function. Black Black Black Black Black Black Black Orange Red Yellow Black Gray White 1.3 m 1.6 m 2m Lifting Stroke 50-Hz Area SW9-1 SW9-2 ON OFF OFF ON ON ON 60-Hz Area SW9-1 SW9-2 OFF OFF ON OFF OFF ON Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. Use the table below to set the intake grill auto-lifting stroke switches. Normal Checker Blue Blue Red Red 2 CONTROL Ceiling cassette compact type (4-way blowoff): TKTC TKTCP28, 36, 45, 56M5 Red Orange Blue White Blue Red Brown Black Orange White Blue White Brown Red Red White Gray Red Red White Red Yellow Blue Yellow Red Black Black Brown Yellow Brown 2-25 Motor Symbol LED-R LED-G F CnA to Z XR1 XR2 XR3 XR4 XR5 H 52H 26 Tf TB < mark mark CL Description LED (Red: Check status indicator) LED (Green: Microcomputer normal t t ) Fuse Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Bimetal switch for H Temperature fuse for H Terminal block (marked {) FASTON terminal Closed-end splicer Capacitor for motors 1 - 4 The circuit marked "*2" above is actually not wired for a panel without an auto-lifting function. Description Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Intake grill auto-lifting stroke setting Control selection for high-ceiling-suspended LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor White White SW6 SW9-1, 2 J1 J2 J3 J4 J5 J6 J7 TrI Val Brown SW5-3 Blue Black SW5-2 White Brown Symbol SW4 SW5-1 Orange Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Louver motor Louver switch Stepping motor (for electronic expansion valve) Spark killer For auto-lifting (for auto-lifting panel) Panel switch Auxiliary relays Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Brown Red Symbol FM1 49F1 CF1 DM FS LM LS SM SK Motors 1 - 4 PS X1 to 8 ThI-A ThI-R Thc SW1 SW2 SW3 Black Motor Blue Motor White Motor Orange (Option) PCB White Orange *2 Brown Black Yellow Pink Orange Blue White Orange Yellow Orange Red White Blue Red Blue Brown White Single-phase (Signal) (Power) Blue Blue Red Blue Red White Red White Orange White Red [Description of symbols] Connection lines between indoor untis To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz Red W hite Normal Check Checker Blue Blue Red Red White Yellow Black Gra y W hite Orange Red Black *1 Option Red *2 Remote control unit White Black Black Black White Black Red Blue Blue The circuit marked "*1" above is actually not provided for a panel without an auto-swinging function. Black Black Black Black Black Black Black Gra y Black Y ellow R ed Ora nge 1.3 m 1.6 m 2m Lifting Stroke 50-Hz Area SW9-1 SW9-2 ON OFF OFF ON ON ON 60-Hz Area SW9-1 SW9-2 OFF OFF ON OFF OFF ON Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. Use the table below to set the intake grill auto-lifting White White AISIN Aisin gas heat pump Ceiling cassette compact type (2-way blowoff): TKTW TKTWP22, 28, 36, 45, 56M5 Brown Blue White Blue Black Black Brown Yellow Brown White Red Red Blue Blue White White Red Red Red Brown Black Orange White Blue Blue Red Motor Orange Motor *2 Motor White White Blue 2-26 White White White White Red Description Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Bimetal switch for H Temperature fuse for H Terminal block (marked {) FASTON terminal Closed-end splicer Capacitor for motors 1 - 4 Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. Symbol XR3 XR4 XR5 H 52H 26 Tf TB < mark mark CL The circuit marked "*2" above is actually not wired for a panel without an auto-lifting function. Blue Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Intake grill auto-lifting stroke setting Control selection for high-ceiling-suspended LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Green: Microcomputer normal status) LED (Red: Check status indicator) Fuse Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Blue Black Motor Red White Brown SW6 SW9-1, 2 J1 J2 J3 J4 J5 J6 J7, 8 TrI Val LED-G LED-R F CnA to Z XR1 XR2 Red Orange SW5-3 Blue Yellow Brown Red Symbol SW5-2 Red Yellow Red Black Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Louver motor Louver switch Stepping motor (for electronic expansion valve) Spark killer For auto-lifting (for auto-lifting panel) Panel switch Auxiliary relays Intake air sensor Heat exchange sensor Thermister accompanying the remote control it No. (10’s place) Unit Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop PCB Gray Red Blue Yellow Brown Orange Orange Orange Yellow Blue Orange White (Option) Blue Blue Pink Blue Blue Brown White Orange Brown Black Symbol FMI1 49F1 CF1 DM FS LM LS SM SK Motors 1 - 4 PS X1 to 8 ThI-A ThI-R Thc SW1 SW2 SW3 SW4 SW5-1 (Signal) (Power) White Red White Red W hite Orange White Red [Description of symbols] Connection lines between indoor units To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red Red Normal Check Checker Blue Blue Red Red Yellow Black *1 Option Black Black White Red *2 Remote control unit Black Black Red White Blue Blue The circuit marked "*1" above is actually not provided for a panel without an auto-swinging function. B la ck Black Black Black B la c k Gray Gray Black B lack B lack B la ck Orange Red Y e llow Red Orange 1.3 m 1.6 m 2m Lifting Stroke 50-Hz Area SW9-1 SW9-2 ON OFF OFF ON ON ON 60-Hz Area SW9-1 SW9-2 OFF OFF ON OFF OFF ON 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. The wiring marked “*1” in this diagram is actually not provided for a panel without an auto-swinging function. 8. The wiring matked “*2” in this diagram is actually not provided for auto-lifting panel specifications. 9. Use the table below to set the intake grill auto-lifting stroke switches. White White 2 CONTROL TKTWP71, 80, 90M5 71S5 (Signal) (Power) Yellow Blue Blue White White Red Red Blue Red Orange Red Orange Blue Blue White Blue Orange Orange White Brown Red Red White Red Red White Red Brown Black Orange White Blue White White Blue Red Motor *2 Motor White Red Red Blue Blue 2-27 White White White Blue White Red Description Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Bimetal switch for H Temperature fuse for H Terminal block (marked {) FASTON terminal Closed-end splicer Capacitor for motors 1 - 4 Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. Symbol XR3 XR4 XR5 H 52H 26H1, 2 Tf TB < mark mark CL The circuit marked "*2" above is actually not wired for a panel without an auto-lifting function. Motor Black Motor Brown Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Intake grill auto-lifting stroke setting Control selection for high-ceiling-suspended LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) White Orange Orange Orange White White White Blue SW6 SW9-1, 2 J1 J2 J3 J4 J5 J6 J7, 8 TrI Val LED-R LED-G F CnA to Z XR1 XR2 Red White *1 Brown White Brown SW5-3 Black Orange Motor for blowoff Internal thermovalve for FM Capacitor for FMI1, 2 Drain motor Float switch Louver motor Louver switch Stepping motor (for electronic expansion valve) Spark killer For auto-lifting (for auto-lifting panel) Panel switch Auxiliary relays Intake air sensor Heat exchange sensor Thermister accompanying the remote control it No. (10’s place) Unit Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid Operation Stop OFF: Operation input Blue Purple Orange Orange Black Red Symbol SW5-2 Brown Yellow Red White Description Brown Yellow Blue Blue Brown Symbol FMI1, 2 49FI1, 2 CFI1, 2 DM FS LM LS SM SK Motors 1 - 4 PS X1 to 8 ThI-A ThI-R Thc SW1 SW2 SW3 SW4 SW5-1 PCB Black Purple Red Yellow Blue Yellow White Black Yellow Pink Blue Gray Orange Brown Orange (Option) Blue Blue Red Blue Red White Red White Orange White Red Black [Description of symbols] Connection lines between indoor units To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red W hite Normal Check Checker Blue Blue Red Red Black *1 Black Black White Red *2 Remote control unit Black White Black Red Blue Blue The circuit marked "*1" above is actually not provided for a panel without an auto-swinging function. Black Black Black Black Black Black Black Black Gra y Option Orange Red Yellow Black Gra y Y ellow Red Ora nge 1.3 m 1.6 m 2m Lifting Stroke 50-Hz Area SW9-1 SW9-2 ON OFF OFF ON ON ON 60-Hz Area SW9-1 SW9-2 OFF OFF ON OFF OFF ON 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. The wiring marked “*1” in this diagram is actually not provided for a panel without an auto-swinging function. 8. The wiring matked “*2” in this diagram is actually not provided for auto-lifting panel specifications. 9. Use7 the table below to set the intake grill auto-lifting stroke switches. White White AISIN Aisin gas heat pump TKTWP112, 140, 160M5, 140S5 Brown Red (Signal) (Power) Blue Blue White White Red Red White White Red Blue Connection lines between indoor units 2-28 SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z Black Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal t t ) Fuse Auxiliary heater Electromagnetic contactor for H Temperature fuse for H Bimetal switch Terminal block (marked {) FASTON terminal Closed-end splicer White SW5-3 White SW5-2 Black Invalid Stop Brown Symbol XR1 XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F H 52H Tf 26 TB < mark mark White Description Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Louver angle selection LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) White Symbol SW3 SW4 SW5-1 Orange Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Louver motor Limit switch Auxiliary relays (for RM) Auxiliary relay (for DM) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Spark killer Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) White (Option) Red Yellow White Yellow Blue Red Orange Red Yellow Gray Brown Orange Yellow Pink White Red Black Orange Symbol FM1 49F1 CF1 DM FS LM LS X1, 2, 3 X4 X5 ThI-A ThI-R Thc SK SM SW1 SW2 Blue Blue Blue White White Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red Red Check PCB Checker Blue Red Blue Red Black White Red White Black Option Remote control unit Red Black Black Blue Blue Black Black Black Red Red Black Black Red Yellow Black Gray Red Yellow Black Gray Black Orange Orange Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal White White 2 CONTROL Ceiling cassette type (1-way blowoff): TKTS TKTSP28, 36, 45, 56M5 Red Brown Blue Blue (Signal) (Power) Black Red Blue Blue White White Red Red White 2-29 Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal t t ) Fuse Auxiliary heater Electromagnetic contactor for H Temperature fuse Bimetal switch Terminal block (marked {) FASTON terminal Closed-end splicer White White White Red White Red Connection lines between indoor units SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z Black White SW5-3 Red Blue Black Symbol XR1 XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F H 52H Tf 26 TB < mark mark Orange SW5-2 Red Yellow Invalid Stop Black Description Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Louver angle selection LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Blue Blue Symbol SW3 SW4 SW5-1 Brown White Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Louver motor Limit switch Auxiliary relays (for FM1) Auxiliary relay (for DM) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Spark killer Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Black White (Option) Brown Red Yellow Red Orange White Orange Brown Yellow Orange Brown Yellow Gray White Yellow Pink White Red Black Orange Symbol FMI1, 2 49F1 CFI1, 2 DM FS LM LS X1, 2, 3 X4 X5 ThI-A ThI-R Thc SK SM SW1 SW2 Blue Blue Blue White Red Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White PCB Check Checker Blue Red Blue Red Black White Red White Black Option Remote control unit Red Black Black Blue Blue Black Black Black Red Red Black Black Red Yellow Black Gray Red Yellow Black Gray Black Orange Orange Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal White White AISIN Aisin gas heat pump TKTSP71M5 71S5 Red Black White White White Blue Blue Blue Red (Signal) (Power) White White White White Red Connection lines between indoor units 2-30 SK < mark mark Red Normal Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse Terminal block (marked {) Thermister accompanying the remote unitt l it Spark killer FASTON terminal Closed-end splicer Black SW6 J3 J4 J5 J6 J7 TrI Val LED-R LED-G F CnA to Z Black Symbol XR1 XR2 XR3 XR4 XR5 H 52H FH Tf TB Thc White SW5-3 Brown Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Red Symbol SW5-2 Black Black Orange Red Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Stepping motor (for electronic expansion valve) Auxiliary relays (for FM1) Auxiliary relay (for DM) Intake air sensor Heat exchange sensor Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Red Yellow Red Symbol FM1 49F1 CF1 DM FS SM X1, 2, 3 X4 ThI-A ThI-R SW1 SW2 SW3 SW4 SW5-1 Blue Black Yellow Black Pink Blue Brown Yellow Brown Red [Description of symbols] (Option) Blue Blue Blue White White Blue White Red Gray The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) White Red PCB White Black Remote control unit Red Black White Red Yellow Black Gray Red Yellow Black Gray Red Orange Orange Red Black Black Red Black Black Black Black Black Black Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. For high static-pressure specifications, interchange th C F2 ( hit ) d C F3 ( d) t Check Checker Blue Blue Red Red 2 CONTROL Built-in type: TKR TKRP22, 28, 36, 45, 56, 71, 90M5 Black Red Red Black White White Blue Blue Red Red (Signal) (Power) White White White White Red Black Black White White Connection lines between indoor units 2-31 SW6 J3 J4 J5 J6 J7 TrI Val LED-R LED-G F CnA to Z Brown SW5-3 White Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse Terminal block (marked {) Thermister accompanying the remote control it killer Spark FASTON terminal Closed-end splicer Red Motor for blowoff Internal thermovalve for FMI1, 2 Capacitor for FMI1, 2 Drain motor Float switch Stepping motor (for electronic expansion valve) Auxiliary relays (for FMI1, 2) Auxiliary relay (for DM) Intake air sensor Heat exchange sensor Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid Operation Stop OFF: Operation input Blue Symbol XR1 XR2 XR3 XR4 XR5 H 52H FH Tf TB Thc SK < mark mark Red Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Brown Orange Red Symbol SW5-2 Red Brown Yellow Red Description Blue Blue Red Red Yellow Black Blue Yellow Black Black Black Orange Brown Yellow Blue Gray Symbol FMI1, 2 49F1 CFI1, 2 DM FS SM X1, 2, 3 X4 ThI-A ThI-R SW1 SW2 SW3 SW4 SW5-1 Blue Blue Brown Black [Description of symbols] Blue Blue (Option) White White Blue Pink Red Red Black Brown The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) White Red PCB Check Black White Black Remote control unit Red Black White Red Orange Red Yellow Black Gray Red Orange Red Yellow Black Gray Black Black Black Black Red Black Black Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. For high static-pressure specifications, interchange the CnF2 (white) and CnF3 (red) connectors. Normal Checker Option AISIN Aisin gas heat pump TKRP112, 140M5 140S5 White Blue Blue White White Red Red Red White (Signal) (Power) Red Connection lines between indoor units 2-32 SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 Symbol TrI Val LED-R LED-G F H 52H 52H0 FH TB Thc < mark mark White SW5-3 Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) White White Symbol SW5-2 Description Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Auxiliary heater Electromagnetic contactor for H Auxiliary relay Temperature fuse Terminal block (marked {) Thermister accompanying the remote control it FASTON terminal Closed-end splicer Black Black Black Orange Orange Orange White Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Float switch Fan controller Auxiliary relays (for FM1) Auxiliary relay (for optional equipments) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Red White Red Blue Red Yellow Red Red Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Black (Option) Black Black Black Yellow Yellow Yellow Black Black (Option) Blue Blue White Red Blue Black Symbol FM1 49F1 CF1 FS FC X1, 2, 3 X4 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 Blue Blue Blue White Red Gray [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White Red Check PCB Black Option Remote control unit White Red Black Red Black White Red Yellow Pink Red Black Black Red Red Black Black Black Orange Red Yellow Black Gray Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal Checker Orange Red Yellow Black Gray 2 CONTROL High static-pressure duct type: TKU TKUP45, 56, 71, 90, 112, 140M5 140S5 White Red Blue Blue White White Red Red Red White (Signal) (Power) White White Red White White Connection lines between indoor units 2-33 SW6 J3 J4 J5 J6 Red SW5-3 Invalid Stop Black Description Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Auxiliary relay Fuse for H Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer White SW5-2 Red Symbol J7 CnA to Z XR1 XR2 XR3 XR4 XR5 H 52H 52H0 FH TB Thc < mark mark White Description Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Red Symbol SW1 SW2 SW3 SW4 SW5-1 White Description Motor for blowoff Internal thermovalve for FMI1,2 Capacitor for FMI1, 2 Float switch Fan controller Auxiliary relays (for FMI1, 2) Auxiliary relay (for optional equipments) Intake air sensor Heat exchange sensor Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Stepping motor (for electronic expansion valve) Red Black Black Black Red Red White Blue Black White Symbol FMI1, 2 49F1 CFI1, 2 FS FC X1, 2, 3 X4 ThI-A ThI-R TrI Val LED-R LED-G F SM Black Black Black Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Black Red Orange Orange Red White Red Blue Black Black Black Orange Red (Option) White Orange Orange Yellow Red Yellow Orange Red Yellow Yellow Black Yellow Yellow Yellow Blue Blue White Red Black (Option) Red Red Blue Blue Blue White Red Gray [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) PCB Check White Black Black Black Black Black Remote control unit Red Black Black Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal Checker Orange Orange Red Red Yellow Yellow Black Black Gray Gray AISIN Aisin gas heat pump TKUP224M5 Red Red Blue Blue White White Red Red Red White (Signal) (Power) White Connection lines between indoor units 2-34 Invalid Stop Description Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Auxiliary relay Fuse for H Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer Black Red White White White SW6 J3 J4 J5 J6 J7 Red White SW5-3 Red Symbol CnA to Z XR1 XR2 XR3 XR4 XR5 H 52H 52H0 FH TB Thc < mark mark White Description Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Red SW5-2 Black Black Black Symbol SW1 SW2 SW3 SW4 SW5-1 White White Description Motor for blowoff Internal thermovalve for FMI1,2 Capacitor for FMI1, 2 Float switch Fan controller Auxiliary relays (for FMI1, 2) Auxiliary relay (for optional equipments) Spark killer Intake air sensor Heat exchange sensor Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Stepping motor (for electronic expansion valve) Black Black Black Black Red Orange Orange Orange Black Blue Red Yellow White Red Blue Red White Black Black Black Red Yellow Yellow Yellow Black Orange Orange Orange Yellow (Option) White Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Black Red Yellow Yellow Blue Blue White Red Red (Option) Red Red Red Symbol FMI1, 2 49F1 CFI1, 2 FS FC X1, 2, 3 X4 SK ThI-A ThI-R TrI Val LED-R LED-G F SM Blue Blue Blue White Red Gray [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red PCB Check Checker Blue Blue Red White Black Remote control unit Red Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal White White 2 CONTROL TKUP280M5 Black Red Red Black Blue Red Black Black Brown Blue Red 2-35 White White Black Brown Blue Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse Terminal block (marked {) Thermister accompanying the remote control it killer Spark FASTON terminal Closed-end splicer White White White White White White Blue Red (Signal) Connection lines between (Power) indoor units SW6 J3 J4 J5 J6 J7 TrI Val LED-R LED-G F CnA to Z Brown White SW5-3 Brown Symbol XR1 XR2 XR3 XR4 XR5 H 52H FH Tf TB Thc SK < mark mark Red Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Red Symbol SW5-2 Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Red Yellow Blue Blue Red Yellow Red Black Orange Brown Yellow Gray Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Stepping motor (for electronic expansion valve) Auxiliary relays (for FM1) Auxiliary relay (for DM) Intake air sensor Heat exchange sensor Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Blue Blue Black Description Blue Blue Gray Symbol FM1 49F1 CF1 DM FS SM X1, 2, 3 X4 ThI-A ThI-R SW1 SW2 SW3 SW4 SW5-1 White White Pink Red Red (Option) White Black [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White Black Remote control unit Red Black Black Black Black Black Black Black Black Black Black Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. For high static-pressure specifications, interchange the CnF2 (white) and CnF3 (red) t PCB Normal Check Checker Option AISIN Aisin gas heat pump Medium static-pressure duct type: TKUM TKUMP22, 28, 36M5 Brown Brown Black Red Red Black (Power) Red Black Black Blue Red Connection lines between indoor units 2-36 White White White Black Brown Blue PCB Normal Check Checker White Black Black Black Remote control unit Red Black Black Black Black Black Black Black Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. For high static-pressure specifications, interchange the CnF2 (white) and CnF3 (red) connectors. White White White White White Blue Red SW6 J3 J4 J5 J6 J7 TrI Val LED-R LED-G F CnA to Z Red Description Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer Red Symbol XR1 XR2 XR3 XR4 XR5 H 52H FH Tf TB T Thc < mark mark Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Red Yellow Gray SW5-3 (Signal) Blue Brown Orange Brown Yellow Gray SW5-2 Blue Blue (Option) Blue Blue Pink White White Blue Blue Red Yellow Red Black Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Drain motor Float switch Stepping motor (for electronic expansion valve) Auxiliary relays (for FM1) Auxiliary relay (for DM) Intake air sensor Heat exchange sensor Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Connector (marked ) Red Red Black Symbol FM1 49F1 CF1 DM FS SM X1, 2, 3 X4 ThI-A ThI-R SW1 SW2 SW3 SW4 SW5-1 White Black [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red 2 CONTROL TKUMP45, 56, 71, 90M5 White Black Red Red Black (Power) 2-37 White White Connection lines between indoor units Red Description Remote control input (No-voltage contact) Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse Terminal block (marked {) Thermister accompanying the remote control unit Spark killer FASTON terminal Closed-end splicer White Blue SW6 J3 J4 J5 J6 J7 Brown SW5-3 Symbol XR5 H 52H FH Tf TB Thc SK < mark mark Brown White Description Transformer Varistor LED (Red: Check status indicator) Fuse LED (Green: Microcomputer normal status) Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Red Symbol TrI Val LED-R F LED-G CnA to Z XR1 XR2 XR3 XR4 Red The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Red Yellow Red SW5-2 Blue Blue (Option) Blue Blue Pink White White Gray Description Motor for blowoff Internal thermovalve for FMI1, 2 Capacitor for FMI1, 2 Drain motor Float switch Stepping motor (for electronic expansion valve) Auxiliary relays (for FMI1, 2) Auxiliary relay (for DM) Intake air sensor Heat exchange sensor Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Red Red Gray Symbol FMI1,2 49F1 CFI1, 2 DM FS SM X1, 2, 3 X4 ThI-A ThI-R SW1 SW2 SW3 SW4 SW5-1 (Signal) [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White PCB Check White Black Remote control unit Red Black Black Black Black Black Black Black Black Black Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. For high static-pressure specifications, interchange the CnF2 (white) and CnF3 (red) connectors. Normal Checker Option AISIN Aisin gas heat pump TKUMP112, 140M5 Blue White Red Red (Signal) (Power) 2-38 Red Symbol TrI Val LED-R LED-G F H SK 52H Tf 26 TB < mark mark Wihte Connection lines between indoor units Description Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Auxiliary heater Spark killer Electromagnetic contactor for H Temperature fuse Bimetal switch Terminal block (marked {) FASTON terminal Closed-end splicer Wihte SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Louver angle selection LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) White SW5-3 Symbol SW5-2 Black (Option) Gray Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Louver motor Limit switch Auxiliary relays (for FM1) Auxiliary relay (for drain motor) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Blue White Orange Black Yellow Red Yellow Brown Yellow Brown Yellow Pink White Red Blue White Description Red Black Orange Symbol FM1 49F1 CF1 LM LS X1, 2, 3 X4 X5 ThI-A ThI-R Thc SM SW1 SW2 SW3 SW4 SW5-1 Blue Blue Blue White Red Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White Check PCB White Black Remote control unit Red Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal Checker 2 CONTROL Ceiling-suspended type: TKE TKEP36, 45, 56M5 Blue Red (Signal) (Power) Blue Blue White White Red Red 2-39 Connection lines between indoor units SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z XR1 SW5-3 SW5-2 Symbol SW5-1 Description ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Louver angle selection LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Invalid Stop Symbol XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F H 52H Tf 26 TB < mark mark Description Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Auxiliary heater Electromagnetic contactor for H Temperature fuse Bimetal switch Terminal block (marked {) FASTON terminal Closed-end splicer White Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Louver motor Limit switch Auxiliary relays (for FM1) Auxiliary relay (for drain motor) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) (Option) White Yellow White Yellow Pink Blue Blue White Red Gray Symbol FMI1, 2 49F1 CFI1, 2 LM LS X1, 2, 3 X4 X5 ThI-A ThI-R Thc SM SW1 SW2 SW3 SW4 Blue Blue Blue White Red Orange Orange Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) White Red PCB Check Checker White Black Remote control unit Red Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal White White AISIN Aisin gas heat pump TKEP71, 90M5, 71S5 Red Blue Blue White White Red Red (Signal) (Power) 2-40 Connection lines between indoor units SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 SW5-3 Description ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Louver angle selection LM4 position control Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Invalid Stop Symbol XR3 XR4 XR5 TrI Val LED-R LED-G F H 52H Tf 26 TB < mark mark Description Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Auxiliary heater Electromagnetic contactor for H Temperature fuse Bimetal switch Terminal block (marked {) FASTON terminal Closed-end splicer White SW5-2 Symbol SW5-1 Orange Orange Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Louver motor Limit switch Auxiliary relays (for FM1) Auxiliary relay (for drain motor) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Thermister accompanying the remote control unit Spark killer Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) (Option) White Yellow Blue White Yellow Pink White White Blue Red Red Gray Symbol FMI1, 2 49F1 CFI1, 2 LM LS X1, 2, 3 X4 X5 ThI-A ThI-R Thc SK SM SW1 SW2 SW3 SW4 Blue Blue Blue White Red Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White PCB Check White Black Remote control unit Red Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal Checker 2 CONTROL TK EP112, 140M5 140S5 Black Black 2-41 White Red Description Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Grill heater Terminal block (marked {) White White Check Description Thermister accompanying the remote control unit FASTON terminal Closed-end splicer Normal Checker PCB Black White White Black Option Remote control unit Red Black Red Red Black Red Black Black Black Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessarypower lines. Use shielded wires if parallel routing is absolutely necessary. Symbol Thc < mark mark White Pink Brown SW6 Yellow White SW5-3 Yellow Brown SW5-2 Black Pink Brown Symbol J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F, FH HD TB Blue Brown Description Motor for blowoff Capacitor for FM1 Auxiliary relays (for FM1) Auxiliary relay (for HD) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Blue Blue White White Symbol FM1 CF1 X1, 2, 3 X4 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 White Red Brown [Description of symbols] (To outdoor unit) Power Red Red White AISIN Aisin gas heat pump Ceiling-suspended oil-resisting type: TKES TKESP80M5 2-42 White Red Black Black SW5-3 Black Black Check Description Grill heater Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer Normal Checker PCB Black White White Black Option Remote control unit Red Black Red Red Black Red Black Black Black Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessarypower lines. Use shielded wires if parallel routing is absolutely necessary. Symbol HD TB Thc < mark mark White SW5-2 Brown Description Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse White White Yellow Yellow White Brown Brown Blue Pink Black Pink Brown Symbol SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F, FH White White Brown Yellow Pink Brown Yellow Pink Brown Description Motor for blowoff Capacitor for FMl Auxiliary relays (for FM1) Auxiliary relay (for HD) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Blue Blue White White Symbol FMl1, 2 CFl1, 2 X1, 2, 3 X4 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 White Red Brown [Description of symbols] (To outdoor unit) Power Red Red White 2 CONTROL TKESP140M5 140S5 (Signal) (Power) 2-43 Connection lines between indoor units SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 TrI Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer White SW5-3 White White Symbol SW5-2 Symbol Val LED-R LED-G F H 52H Tf 26 TB Thc SK < mark mark Orange Orange Normal Description Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Auxiliary heater Electromagnetic contactor for H Temperature fuse Bimetal switch Terminal block (marked {) Thermister accompanying the remote control unit Spark killer FASTON terminal Closed-end splicer Gray Description Motor for blowoff Internal thermovalve for FMl Capacitor for FMl Louber motor Limit switch Auxiliary relays (for FM1) Auxiliary relay (for optional units) Auxiliary relay (for LM) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Red White Symbol FM1 49Fl CFl LM LS X1, 2, 3 X4 X5 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 Blue Red Yellow The heater circuit enclosed in a dotted line above assumes that an optional electric heater is installed. Black Blue Orange White Yellow Black Orange Orange (Option) Blue Blue Pink Blue Blue Yellow White White Blue Red Red Orange [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz (With electric heater mounted: 3-phase 200 VAC, 50/60Hz) Red White PCB Remote control unit Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Check Checker Option AISIN Aisin gas heat pump Wall-mounted type: TKK TKKP28, 36, 45, 71M5 (Signal) (Power) White Blue Red 2-44 Symbol Val LED-R LED-G F TB Thc < mark mark White Connection lines between indoor units SW5-2 Red Black SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 XR5 TrI Blue Red Yellow Description ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Black Blue Symbol SW5-3 Black Normal Check Checker Description Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer Black Black White Description Motor for blowoff Internal thermovalve for FMl Capacitor for FMl Auxiliary relays (for FM1) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop ON: Temperature setting +3°C OFF: Normal Blue Blue Gray Symbol FM1 49Fl CFl X1, 2, 3 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 Blue Blue Red White Red White Red Black Remote control unit White Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. PCB Red Option Floor-standing lowboy: TKFL TKFLP28, 45, 56, 71M5 [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz Red White 2 CONTROL Floor-standing lowboy (concealed type): FKFU TKFUP28, 45, 56, 71M5 (Signal) (Power) Symbol SW5-1 Connection lines between indoor units 2-45 SW6 J3 J4 J5 J6 J7 CnA to Z XR1 SW5-3 Invalid Stop Symbol XR2 XR3 XR4 XR5 TrI Val LED-R LED-G F TB Thc < mark mark Description Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) Thermister accompanying the remote control unit FASTON terminal Closed-end splicer White SW5-2 Description ON: Operation input Reversing OFF: Operation input Operation ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Black Description Motor for blowoff Internal thermovalve for FM1 Capacitor for FM1 Float switch Fan controller Auxiliary relays (for FM1) Auxiliary relay (for optional equipments) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) (Option) Black Symbol FM1 49F1 CF1 FS FC X1, 2, 3 X4 ThI-A ThI-R SM SW1 SW2 SW3 SW4 Blue Blue Blue Blue White Red White Red Gray [Description of symbols] To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz Red White Red Normal PCB White Black Option Remote control unit Red Orange Red Yellow B la ck G ra y Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Check Checker Red Yellow B la ck G ra y Orange AISIN Aisin gas heat pump Air feed processing unit: TKUS TKUSP90, 140M5 140S5 Red Red Red 2-46 Red Connection lines between indoor units Description Motor for blowoff (air supply switch) Motor for blowoff (exhaust switch) Electromagnetic contactor (for FMIS, E) Internal thermovalve (for FMIS, E) Capacitor (for FMIS, E) Water supply solenoid valve Noise killer Stepping motor (for electronic expansion valve) Auxiliary relays (for FM1) Auxiliary relay (for DM) Auxiliary relay (heating output) SW6 SW5-3 SW5-2 Red Symbol J3 J4 J5 J6 J7 TrI Val LED-R LED-G F TB < mark mark CnA to Z ST1 - 6 HU PCB White Description Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) FASTON terminal Closed-end splicer Connector (marked ) Butt splicer Temperature regulator (200 V, locally procured) Red Symbol FMIS FMIE 52F1 49F1 CF1 20V NK SM X1, 2, 3 X4 XHU1 Blue Blue White Red White [Description of symbols] Red Description Auxiliary relay (operation output) Intake air sensor Heat exchange sensor Select switch (air supply external static pressure) Select switch (exhaust external static pressure) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid Operation Stop OFF: Operation input ON: Temperature setting +3°C OFF: Normal ON: Filter sign ON OFF: Filter sign OFF Heat pump type selection Black Symbol XHU2 ThI-A ThI-R SS SE SW1 SW2 SW3 SW4 SW5-1 Black Red Red Red Red Red Centralized diversion controller (Signal lines) (Power) Black Blue Blue Red Red Black Option (Signal lines) (Signal) Left side of the control box Yellow Red Low static press. Red Red Exhaust Gray Gray White Red Red High static press. Low static press. Air supply Blue Blue White Red Red High static press. To outdoor unit (signal lines) Power requirements: Single-phase 200 VAC, 50/60 Hz Red White Check Red Red White Black Remote control unit White Black Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. 7. Set the blowoff motor rotational speed according to the particular static pressure specifications of the external equipment by operating the select switches (SS: Air supply switch, SE: Exhaust switch). Normal Checker Yellow 2 CONTROL Outside-air processing unit: TKSA TKSAP28, 45, 56M5 2-47 SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Symbol XR5 TrI Val LED-R LED-G F TB Thc SK < mark mark Checker PCB White Black Red Red Black Black Black Black Red Black Black White Black Remote control unit Red Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Normal Check Description Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) Thermister accompanying the remote control unit Spark killer FASTON terminal Closed-end splicer White SW5-3 Symbol SW5-2 Blue Description Motor for blowoff Internal thermovalve for FM Electromagnetic contactor for FM Auxiliary relays (for FM) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop White Symbol FM 49F 52F X1, 2, 3 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 [Description of symbols] White Blue Blue Black White Gray Blue Blue Red To outdoor unit (signal lines) Highspeed White White Blue Red Red Red Yellow Standard Phase T Phase R Power requirements: 3-phase 200 VAC, Phase S 50/60 Hz Red White AISIN Aisin gas heat pump Floor-standing duct plenum type: TKFD, TKFP TKFPP140M5 2-48 SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 SW5-3 Symbol SW5-2 Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Symbol XR5 TrI Val LED-R LED-G F TB Thc SK < mark mark White Description Motor for blowoff Internal thermovalve for FM Electromagnetic contactor for FM Auxiliary relays (for FM) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Normal Check Checker Description Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) Thermister accompanying the remote control unit Spark killer FASTON terminal Closed-end splicer White Symbol FM 49F 52F X1, 2, 3 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 Blue Blue Red Blue White White Blue Highspeed White Red Gray [Description of symbols] Blue White Red Blue Red Yellow Standard Phase T Phase S Phase R Black To outdoor unit (signal lines) Power requirements: 3-phase 200 VAC, 50/60 Hz Black White Black Remote control unit Red Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. PCB Red White Black Red Black Black Black Red Black Black Option 2 CONTROL TKFPP224, 280M5 280S5 2-49 SW6 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 Description ON: Temperature setting +3°C OFF: Normal ON: Drain motor ON OFF: Drain motor OFF Heat pump type selection Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Symbol XR5 TrI Val LED-R LED-G F TB Thc SK < mark mark Blue SW5-3 Symbol SW5-2 Normal Check Checker PCB Description Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Terminal block (marked {) Thermister accompanying the remote control unit Spark killer FASTON terminal Closed-end splicer White Description Motor for blowoff Overcurrent relay for FM Electromagnetic contactor for FM Auxiliary relays (for FM) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop White Symbol FM 51F 52F X1, 2, 3 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 White Gray Blue White Red Red Blue Blue White Red Red Yellow [Description of symbols] Phase T Phase S Phase R Black To outdoor unit (signal lines) Power requirements: 3-phase 200 VAC, 50/60 Hz Black White Black Remote control unit Red Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. 6. Do not route the remote control lines in parallel with other power lines. Use shielded wires if parallel routing is absolutely necessary. Red White Black Red Black Black Black Red Black Black Option AISIN Aisin gas heat pump TKFDP224, 280M5 280S5 White Blue (Signal) (Power) White White White White White Red Red Red Red Red 2-50 Symbol XR5 TrI Val LED-R LED-G F SK TB < mark mark H 52H FH Tf White Connection lines between indoor units SW6 J1 J2 J3 J4 J5 J6 J7 CnA to Z XR1 XR2 XR3 XR4 Red White Description ON: Temperature setting +3°C OFF: Normal ON: – OFF: Drain motor OFF Heat pump type selection – – Thermo-OFF fan control Filter sign Operation enable/inhibit selection Expansion valve angle selection Type selection Connector (marked ) Operation output (12 VDC output) Heating output (12 VDC output) Thermo ON output (12 VDC output) Check output (12 VDC output) Blue Red Yellow Normal White Description Remote control input (No-voltage contact) Transformer Varistor LED (Red: Check status indicator) LED (Green: Microcomputer normal status) Fuse Spark killer Terminal block (marked {) FASTON terminal Closed-end splicer Auxiliary heater Electromagnetic contactor for H Fuse for H Temperature fuse White SW5-3 Symbol SW5-2 Black Orange White Yellow Pink Black Blue Orange Orange Description Motor for blowoff (wih thermovalve) Capacitor for FM1 Louver motor Auxiliary relays (for FM1) — Auxiliary relays (for LM) Intake air sensor Heat exchange sensor Stepping motor (for electronic expansion valve) Unit No. (10’s place) Unit No. (1’s place) Outdoor unit No. (10’s place) Outdoor unit No. (1’s place) ON: Operation input Reversing Invalid OFF: Operation input Operation Stop Red Gray Symbol FM1 CF1 LM X1, 2, 3 X4 X5 ThI-A ThI-R SM SW1 SW2 SW3 SW4 SW5-1 Blue Blue Blue White Red Orange [Description of symbols] To outdoor unit (signal lines) Power supply for electric heater Power requirements: Single-phase 200 VAC, 50/60 Hz Red White PCB Black Black Operating panel Red White White Black Black Black Black Red Red Red Black Black Option Notes: 1. This diagram shows only indoor unit circuits. 2. The dotted line (- - - ) denotes on-site wiring. 3. “TB” A and B denote 5-V signal line terminal blocks. 4. Connect 0.75 - 2.00 mm2 × 2-conductor cables to A and B to connect signal lines to the outdoor unit and to connect signal lines between indoor units. 5. Route the signal lines separately from the power lines. Check Checker 2 CONTROL Floor-standing type: TKF TKFP80M5, 140M5 140S5 Blue Blue AISIN Aisin gas heat pump 3 TROUBLE DIAGNOSIS AND REPAIR Chapter 3 TROUBLE DIAGNOSIS AND REPAIR 3.1 Circuit Base Board Maintenance Functions 3.2 Trouble Items and Diagnosis 3.1.1 Error Codes, Contents, and Major Likely Causes 3.3 3.4 Diagnostic Items Trouble Diagnosis and Check 3.4.1 If the System Does Not Operate 3.4.2 If the Starter Does Not Operate 3.4.3 If the Engine Does Not Start 3.4.4 If the Engine Stalls 3.4.5 Coolant Temperature Alarms 3.4.6 Oil Pressure Alarms 3.4.7 Engine Speed Too High Alarm 3.4.8 High-Pressure Alarms During Cooling 3.4.9 High-Pressure Alarms During Heating 3.4.10 Refrigerant Low-Pressure Alarms 3.4.11 Refrigerant Discharge Temperature Alarms 3.4.12 Communications Trouble and Indoor Unit Circuit Trouble 3.4.13 If Sufficient Cooling Cannot Be Obtained 3.4.14 If Sufficient Heating Cannot Be Obtained 3-1 3 TROUBLE DIAGNOSIS AND REPAIR 3.1 Circuit base board maintenance functions Six 7-Segment LED on the outdoor unit control board indicate operation hours and operation situation etc.. In addition, this maintenance function block is able to give mandates for the individual operation of indoor units. 1) Summary of maintenance functions of the control board Mode functions and display Mode Main function Mode LED Operation Time Display of operation time OFF Monitoring Input / output data signal indicator Green light Command Operation command / rotational speed command indicator Yellow light Check Memory data updating and independent activation of various Red light components In switching the other mode during Command mode, mode LED is lighting color corresponding each mode and blinking yellow five times alternately. ex. In monitoring mode, mode LED is blinking green and five times yellow alternately. Description for error signal (error LED) Outdoor unit failure Flashing continuously Periodic inspection Flashing continuously Forcible addition of engine oil Flashing 9 times Error stop Flashing 7 times Intake air avoidance Flashing 6 times Exhaust air avoidance Flashing 5 times High pressure avoidance Flashing 4 times Water temperature avoidance Flashing 3 times Low pressure avoidance Flashing 2 times Normal OFF High Priority for display Low 10 times flashing is one cycle (ex. Flashing 7 of 10 times) How to change to each mode Operation mode display Monitor mode Command mode Check mode Press MODE switch for 1 seconds or more Press Set and Clear switch for 2 seconds or more It is possible to change to CHECK mode more 3 minutes after power on or compressor off. Note) It is impossible to change to COMMAND mode and CHECK mode 10 minutes after connected or disconnected to PC checker. 7 segments LED The description of 7 segments LED is as follows. If necessary, code no. and indoor unit address is lighting alternately. Data 3-2 AISIN Aisin gas heat pump Code Number List Code No. 01-10 11 12 13 15 16 18 19 20 21 23 24 27 28 29 31 32 34 39 40 41 42 43 50 51 52 53 56 57 58 59 60 63 66 68 69 70 71 72 73 74 75 76 79 90 91 92 94 95 96 97 98 99 Monitor Mode Function Previous error 1-10 -1 Actual engine RPM **** min -1 Requested engine RPM **** min -1 Calculated engine RPM **** min Throttle valve angle *** step Fuel gas adjustment valve angle **** step Igniter output ( ) Liquid quantity adjustment valve angle **** step Powered three-way valve angle *** step Quantity adjustment valve angle **** step Output of powered equipment for Ventilator 1 *** % Output of powered equipment for Ventilator 2 Hi or Lo: *** % Output status Avoidance Status External Switch status Individual parts operation [ON] Individual parts operation [OFF] Water filling mode (On/Off) Outdoor unit capacity *** KW Engine operation time **** hours hours/10 Previous periodic check time **** hours hours/10 Right compressor operation time **** hours hours/10 Left compressor operation time **** hours hours/10 Starter on/off count **** times times/100 Engine on/off count **** times times/100 Right compressor on/off count **** times times/100 Left compressor count **** times times/100 Periodic inspection reset (On setting) Automatic address erase (On setting) Main micro computer version **.** Engine micro computer version **.** High pressure *.** MPa High-pressure equivalent temperature ** Engine Cooling water temperature ** Engine exhaust air temperature *** Heat exchanger liquid temperature -** Accumulator inlet temperature -** Right discharge temperature *** Left discharge temperature *** Gas pipe temperature -** Intake temperature -** Engine room temperature -** Outside temperature -** Target temperature in heating and cooling *** Indoor unit individual request frequency *** Hz Indoor unit answer frequency *** Hz Indoor unit request frequency *** Hz Indoor unit expansion valve angle (*** steps, controlling oil return) Indoor unit quantity **.* Kw Indoor unit target heat exchanger temperature -** Indoor unit control heat exchanger temperature -** Indoor unit intake temperature *** Indoor unit operation status only indoor unit expansion valve fully open status 3-3 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Command Mode Check Mode Remark ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ CN7(8-3-4 pin) CN7(9 pin) CN7(13-14 pin) CN6(1-2 pin) CN6(3-4 pin) CN6(7-8pin ) CN6(5-6pin) CN6( 9-10 pin) CN6(11-12 pin) CN6(13-14 pin) CN6(15-16 pin) ○( 1) ○ 3 TROUBLE DIAGNOSIS AND REPAIR 2) Operating hours display mode This mode will be set when the outdoor unit in power on. This mode will also be set when no maintenance function is operated for at least 10 minutes in any other mode Function of each switch Switch status Switch Function / 7 segments display description No setting Display operation hours Display error status (error code) In case of multiple errors, the errors are displayed alternately Left 2 digits error main code Right 2 digits error sub code Ex Error code Case “80-0” … Case “5-20” … Case “no error” … Only pressing Code № Only pressing Code no. Display error stop status (Error Code). (In case of multiple errors, the errors are displayed alternately. The description is the same as the case of “Code no. UP) Display indoor units operation / stop status by 7 segments. Indoor unit 0 is the minimum indoor unit address. In case of the number of connected indoor units is 16 sets or less, operating indoor Indoor unit unit LED is lighting. Indoor unit Indoor unit Indoor unit Indoor unit In case the number of connected indoor units is more than 17 sets, display as follows every 2 seconds alternately. The operating indoor unit LED is lighting. Indoor unit Indoor unit Only pressing “Selecting indoor unit” Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Display of indoor units which number is more than 16. Only pressing “Mode Selecting “ Only pressing “Clear” Only pressing “Set” Press both Indoor unit select Set for one second or more Change mode (-> monitor mode) No function Display of each part output status by 7 segments LED Please refer to Code no. 27 for the description Operating all of connected indoor units Displaying as follow. Sending operating command, operating mode command and setting temperature to all of indoor units. In more than 23 , operating in cooling (Setting temp. 18 ) and in less than 23 , operating in heating (setting temp.30 ) Stopping all of connected indoor units. Displaying as follows. Press both Indoor unit select Clear for 1 second or more Reset in error. Displaying as follows. Press both Code no. Clear for 1 second or more 3-4 AISIN Aisin gas heat pump 3) Monitor Mode This mode displays each input / output status. Function of each switch Switch status Only pressing Code № Only pressing Code no. Only pressing “Selecting indoor unit” Only pressing “Mode Selecting Only pressing “Clear” Only pressing “Set” Switch Function / 7 segments display description Change code numbers from small number to large number. 00 → 01 → … → 98 → 99 → 00 → 01 → … Change code number from large number to small number. 00 → 99 → → 98 … → 01 → 00 → 99 → 98 → … In check each indoor unit data, select the unit you want to display. In pushing the switch, the address of indoor unit is changing. (Use in case more than the code no. 80.) The minimum of indoor unit addressÆ…→ The maximum address→ - - → The minimum address Change the mode (-> Command mode) Do not use Do not use Code number codes in monitor mode Code no. 01 10 11 12 13 15 16 17 18 19 20 21 23 24 25 27 28 29 39 40 41 42 43 50 51 52 53 58 59 60 63 66 68 69 70 71 72 73 74 75 76 79 90 91 92 94 95 96 97 98 99 Function Previous error 1-10 -1 Actual engine RPM **** min -1 Requested engine RPM **** min -1 Calculated engine RPM **** min Throttle valve angle *** step Fuel gas adjustment valve angle *** step Engine igniter angle -*** ° Igniter output * Liquid quantity adjustment valve angle **** step Calculated powered three-way valve angle *** step Quantity adjustment valve angle **** step Output of powered equipment for Ventilator 1 *** % Output of powered equipment for Ventilator 2 Hi-Lo *** % Cooling water pump output * Output status Avoidance Status External Switch status Capacity of outdoor unit *** KW Engine operation time **** hours hours/10 Previous periodic check time **** hours hours/10 Right compressor operation time **** hours hours/10 Left compressor operation time **** hours hours/10 Starter on/off count **** times times/100 Engine on/off count **** times times/100 Right compressor on/off count **** times times/100 Left compressor on/off count **** times times/100 Main micro computer version **.** Engine micro computer version **.** High pressure *.** MPa High-pressure equivalent temperature ** Engine cooling water temperature ** Engine exhaust air temperature *** Heat exchanger liquid temperature -** Accumulator intake temperature -** Right outlet discharge temperature *** Left outlet discharge temperature *** Gas pipe temperature -** Intake temperature -** Engine room temperature -** Outside temperature -** Target temperature in heating and cooling ** Indoor unit individual request frequency *** Hz Indoor unit answer frequency *** Hz Indoor unit request frequency *** Hz Indoor unit expansion valve angle *** step Indoor unit quantity **.* Kw Indoor unit goal heat exchanger temperature ** Indoor unit control heat exchanger temperature ** Indoor unit intake temperature ** Indoor unit operation status 3-5 3 TROUBLE DIAGNOSIS AND REPAIR Command Mode This mode allows the instruction of the indoor units and engine revolutions. The function of each switch Switch status Only pressing Code № Only pressing Code no. Only pressing “Selecting indoor unit” Only pressing “Mode Selecting “ Only pressing “Clear” Only pressing “Set” Switch function/ 7 segments LED display description Change code numbers from small number to large number. 00 → 01 → … → 98 → 99 → 00 → 01 → … Change code number from large number to small number. 00 → 99 → → 98 … → 01 → 00 → 99 → 98 → … In check each indoor unit data, select the unit you want to display. In pushing the switch, the address of indoor unit is changing. (Use in case more than the code no. 80.) The minimum of indoor unit addressÆ…→ The maximum address→ - - → The minimum address Change the mode (-Æ) Operation hours display) Clear the set data. In setting operation, the current operation status is displayed and, in other indications, the previous status before set is selected. Fix the set data. Ex. In case of setting indoor unit operation, in pushing the switch finally, the data is sent to the indoor unit. Code numbers List of Command mode Code no. Function Min. to max. -1 ± Min. to max. Requested engine RPM **** min 13 Calculated engine RPM **** min 20 21 23 24 99 Set Range ± 12 19 Width -1 Liquid quantity adjustment valve angle **** step Calculated powered three-way valve angle *** step Quantity adjustment valve angle **** step Output of powered equipment for Ventilator 1 *** % Output of powered equipment for Ventilator 2 **** % Indoor unit operation status *** ―― 60 to 2000 ―― 12 to 820 ―― 60 to 2000 ± 0 to 100 ± Hi/Lo: 0 to 100 ―― 3-6 ―― AISIN Aisin gas heat pump Check mode Renew the memorized data and indicate each unit operation. Function of each switch Switch status Only pressing Code № Only pressing Code no. Only pressing “Selecting indoor unit” Only pressing “Mode Selecting “ Only pressing “Clear” Only pressing “Set” Switch function/ 7 segments LED display description Change code numbers from small number to large number. 00 → 01 → … → 98 → 99 → 00 → 01 → … Change code number from large number to small number. 00 → 99 → → 98 … → 01 → 00 → 99 → 98 → … In checking each indoor unit data, select the unit you want to display. In pushing the switch, the address of indoor unit is changing. (Use in case more than the code no. 80.) The minimum of indoor unit addressÆ…→ The maximum address→ - - → The minimum address Change the mode (-Æ) Operation hours display) Clear the set data. In setting operation, the current operation status is displayed and, in other indications, the previous status before set is selected. Fix the set data. Ex. In case of setting indoor unit operation, in pushing the switch finally, the data is sent to the indoor unit. Code no. list in Check mode Code no. Function Set range 15 Throttle valve angle *** step 16 Fuel gas adjustment valve angle *** step 10 to 140 19 Liquid quantity adjustment valve angle **** step 60 to 2000 20 Calculated powered three-way valve angle *** step 12 to 820 21 Quantity adjustment valve angle **** step 60 to 2000 23 Output of powered equipment for Ventilator 1 *** % 0 to 100 24 Output of powered equipment for Ventilator 2 **** % Hi/Lo:0 to 100 31 Individual part operation (ON) 32 Individual part operation (Off) 34 35 90 to 493 On Off On / Off Water filling mode (On/Off) Engine oil supply mode On setting On 40 Engine operation time 41 Previous periodic check time **** hours hours/10 0 to 6553 42 Right compressor operation time **** hours hours/10 0 to 6553 43 Left compressor operation time **** hours hours/10 Starter on/off count **** times times/100 0 to 6553 50 51 Engine on/off count **** times times/100 0 to 5898 52 Right compressor on/off count **** times times/100 0 to 5898 53 Left compressor on/off count **** times times/100 0 to 5898 56 Periodic inspection reset On setting On 57 Automatic address erase On setting On 94 Indoor unit expansion valve angle ***step **** hours hours/10 3-7 0 to 6553 0 to 5898 Only full open 3 TROUBLE DIAGNOSIS AND REPAIR Instruction Description Code № 01 02 03 04 05 06 07 08 09 10 12 Instruction Description ●Previous error 1-10 ○Monitor Mode ex. Engine micro computer communication error (84-3) when the operation time is 9130 hours ↓ ↑Flashing in 2 seconds ●Requested Engine RPM ○Command Mode In pushing Set ”Jido”is blinking, push Code no. UP blinking. maximum ”Jido”is blinking. Code № Down The current engine RPM is Ex) 900 min-1 In pushing Code no. min-1 In pushing Code no. min-1 In pushing Code no. Code no. “Jido”is blinking Push the ”Set” to fix the RPM. Set range: From the minimum requested RPM to the The display changes blinking to flashing continuously. ex 1250min-1 13 ●Calculated Engine RPM ○Command Mode In pushing “Set”, “Jido”is blinking. When “Jido” is blinking, push“ Code no. UP”+ “Code no. Down” The current calculated RPM is blinking. ex min-1 In pushing ”Code no. UP”, min-1 In pushing “Code no. Down”, min-1 In pushing ”Code no. UP”+ “Code no. Down” “Jido” is blinking. Push “Set”to fix the RPM. Set range :From the minimum to the maximum The display changes from blinking to flashing continuously. Ex 1250 min-1 3-8 AISIN Aisin gas heat pump 15 ●Throttle valve angle ○Check Mode In pushing “set, “Jido”is blinking. When “Jido”is blinking, push “Code no. UP”+ ”Code no. Down” The hundred’s place of the current throttle valve angle is blinking. ex step In pushing ”Set”, the blinking place changes from the hundred’s place, the ten’s place to one place of the current angle. In pushing “Code no. UP”, → … → → In pushing “Code no. DOWN”, →… → →…→ → →…→ When the one place is blinking, push “Set”. The display is blinking. Then, push “Set” to fix the angle. (set range: 90 step to 493 step) The display change from blinking to flashing. 16 ex 99steps ●Fuel gas adjustment valve angle ○Check Mode When push “Set”, “Jido”is blinking. 19 When “Jido”is blinking, push “Code no. UP”+ ”Code no. Down” The hundred’s place of the current fuel gas adjustment valve angle is blinking. Ex) step In pushing ”Set”, the blinking place changes from the hundred’s place, the ten’s place to one’s place of the current angle. In pushing “Code no. UP”, → … → → →… → In pushing “Code no. DOWN”, →… → → → …→ When the one’s place is blinking, push “Set”. The display is blinking. Then, push “Set” to fix the angle. (set range: 10 steps to 140 steps) The display is from blinking to flashing continuously Ex. 123 steps ●Liquid quantity adjustment valve angle ○Command mode / Check mode In pushing “Set”, “Jido” is blinking. When “Jido” is blinking, push “Code no. UP”+ ”Code no. Down” The thousand’s place of the current refrigerant liquid quantity angle is blinking Ex. 60 steps In pushing ”Set”, the blinking place changes from the thousand’s place, the hundred’s place, the ten’s place to one’s place of the current angle. In pushing “Code no. UP”, → … → → → …→ In pushing “Code no. DOWN”, → … → → →…→ When the one’s place is blinking, push “Set”. The display is blinking. Then, push “Set” to fix the angle. (set range: 60 steps to 2000 steps) The display is from blinking to flashing 3-9 3 TROUBLE DIAGNOSIS AND REPAIR continuously. 20 Ex.1093 steps ●Powered three-way valve angle ○Command mode Check mode In pressing “Set”, “Jido” is blinking. Down” 21 When “Jido” is blinking, push “Code no. UP”+ ”Code no. The hundred’s place of the three-way valve angle is blinking. ex 750 steps powered In pushing ”Set”, the blinking place changes from the thousand’s place, the hundred’s place, the ten’s place to the one’s place of the current angle. In pushing “Code no. UP”, → … → → → … → In pushing “Code no. DOWN”, →… → → → …→ When the one’s place is blinking, push “Set”. The display is blinking. Then, push “Set” to fix the angle.(set range: 12 steps to 820 steps) The display changes from blinking to flashing continuously. Ex. 60 steps ●The capacity adjustment valve angle ○Command mode/Check mode In pressing “Set”, “Jido” is blinking. Down” When “Jido” is blinking, push “Code no. UP”+ ”Code no. The thousand’s place of the current capacity adjustment valve angle is blinking. Ex 60 step In pushing ”Set”, the blinking place changes from the thousand’s place, the hundred’s place, the ten’s place to the one’s place of the current angle. In pushing “Code no. UP”, → … → → →…→ In pushing “Code no. DOWN”, →… → → → …→ When the one’s place is blinking, push “Set”. The display is blinking. Then, push “Set” to fix the angle. (set range: 60 steps to 2000 steps) The display changes from blinking to flashing continuously. Ex step 3-10 AISIN Aisin gas heat pump 23 ●Output of electric equipment for Ventilator 1 ○Command mode / Check mode In pushing “Set”, “Jido”is blinking. When “Jido”is blinking, push “Code no. UP”+ ”Code no. Down” The current duty ratio of the electrical equipment for ventilator 1 is blinking. ex The current duty ratio of the electrical equipment for ventilator 1 is 10%. In pressing “Code no. UP” In pressing “Code no. DOWN” In pressing “Code no. UP”+”Code no. DOWN”, “Jido” is blinking. Press “Set” to fix the setting. (range: ) The display changes from blinking to flashing continuously. ex The current duty ratio of the electrical equipment for ventilator 1 is 100%. 24 ●Output of electric equipment for Ventilator 2 ○Monitor mode Ex) The electrical equipment of ventilator 2 is stopped. Ex The duty ratio of the electrical equipment for ventilator 2-L is 100%. Ex The duty ratio of the electrical equipment for ventilator 2-H is 30%. ○Command mode / check mode In pressing “Set”, “Jido” is blinking. Down” When “Jido” is blinking, push “Code no. UP”+ ”Code no. The L or H, the current status of the electrical equipment for the ventilator 2 is blinking. Ex) The duty ratio of the electrical equipment for ventilator 2-L is 50%. When the L or H is blinking, If pressing “Code no. UP”, the electrical equipment for ventilator 2-H is set. If pressing “Code no. DOWN”, the electrical equipment for ventilator 2-L is set. If pressing “Set” , the number is blinking. When the number is blinking, If pressing “Code no. UP”, the duty ratio become plus 5%. If pressing “Code no. DOWN”, the duty ratio become minus 5%. If pressing “set”, all of the data is blinking. After that, pressing “set”, the data is fixed. (set range: 0% to 100%) The display changes from blinking to flashing continuously. ex) The duty ratio of the electrical equipment for ventilator 2-H is 20% 3-11 3 TROUBLE DIAGNOSIS AND REPAIR 3-12 AISIN Aisin gas heat pump 27 ●Output Description ○Monitor Mode The description of indicator is following. Four-way changeover valve Electrical equipment for ventilator 1 Hot gas bypass Oil supply Electromag Electromag Oil return valve 1 Tap 1 valve 1 netic valve netic valve3 valve 1 Electrical Drain filter Ventilator fan equipment for heater ventilator 2-L Electromag netic valve4 28 Comp. heater Electrom agnetic valve2 Starter Gas Comp. electromag R netic Starter Transforme Gas Comp. electromag Oil return Hot gas bypass Oil supply Tap 2 L va lve 2 netic valve 2 valve 2 valve2 Coolant heater Electrical equipment for Coolant pump ventilator 2-H ●Avoidance Description ○Monitor mode The details of display are as follows. Engine coolant avoidance Error waiting Intake avoidance Warming-u p complete 29 HighLowpressure pressure avoidance avoidance Discharge avoidance ●External switch status ○Monitor mode The details of display is as follows Spare switch at main side High-pressure switch Gas electromagn etic valve Origin of three-way valve Inverter error signal Spare switch at engine side 3-13 Engine oil level H Engine oil level L Low-pressure switch Oil pressure switch 3 TROUBLE DIAGNOSIS AND REPAIR 31 ●Operating each part “ON” ○Check mode The place for each part is as follows. 1. Compressor R 2. Compressor L 3. Gas electromagnetic valve 1 4.Gas electromagnetic valve 2 5. Starter 6. Starter transformer 7. Coolant pump 12 Electrical equipment for ventilator 1 13 Electrical equipment for ventilator 2-L 14 Electrical equipment for ventilator 2-H 15 Hot gas bypass valve 17. Oil return valve 1 18. Oil return valve 2 19. Compressor heater 20. Drain filter heater 21 Coolant heater 26 Four-way changeover valve 27 Ventilator fan 32 When pressing “Set”, one segment is blinking. Then, if pressing “Code no, UP”, each segment is blinking from small to large number one by one, like 1→2→ … →27→28→1. If pressing “Code no. DOWN”, each segment is blinking from large to small number one by one, like 1→28→27→ … →2→1 When the segment of the part which you want to turn on is blinking if “Set” is pressed, the part is operated. The operation time of Starter is 5 seconds, those of other parts are 3 minutes. ●Individual operation of parts “OFF” 1 ○Check mode Position of each part is following. 1. Compressor R, 2. Compressor L, 3. Fuel gas electromagnetic valve 1, 4. Fuel gas electromagnetic valve 2, 5. Starter, 6. Starter transformer 7. Coolant pump, 12 Electrical equipment for ventilator 1, 13 Electrical equipment for ventilator 2-L, 14 Electrical equipment for ventilator 2-H, 15 Hot gas bypass valve 1, 16 Hot gas bypass valve 2, 17 Oil return valve 1, 18 Oil return valve 2 19 Compressor heater, 20 Drain filter heater, 21 Coolant heater, 26 Four-way changeover valve, 27. Ventilator fan When pressing “Set”, one segment is blinking. Then, if pressing “Code no, UP”, each segment is blinking from small to large number one by one, like 1→2→ … →27→28→1. If pressing “Code no. DOWN”, each segment is blinking from large to small number one by one, like 1→28→27→ … →2→1 When the segment of the part which you want to turn on is blinking, if “Set” is pressed, the part is operated. When all segments are blinking, if “set” is pressed, all parts are stopped. 3-14 AISIN Aisin gas heat pump 34 ●Supply water mode ○Check mode Display of the current supply water status. Ex.) Water supply OFF The display is flashing in pressing “Set” When pressing “Code no. UP” or “Code no. DOWN”, ON and OFF is displayed alternately Press “Set” to fix. Setting range ON or Off The display change from flashing to lighting 35 ex Water supply on Supplying water for 5 minutes at maximum.. ●Engine oil supply mode ○Check mode OFF is displayed on the data display. ↓ Pressing “Set”. “Oil” is blinking on the data display ↓Pressing “Set” for 2 seconds or more, the data is fixed. “Oil on” is displayed on the data display. 40 41 42 43 Keep this mode by power-off. It is invalid to turn on the switch. ●Engine operation time(40) ●Previous periodic inspection time(41) ●Compressor R operation time(42) ●Compressor L operation time(43) ○Check mode The present operation time is indicated Ex) Engine operation time is 1350 hours/10. When pressing “Set”, each digit is blinking from thousand’s place →hundred’s place → ten’s place → one place. If pressing “Code no. UP” , the number changes from small to larger number, like 0→ … →9→0→ … →9. If pressing “Code no. down”, the number changes from small to larger number, like 9→…→0→9→…→0. When the one’s place is blinking and “Set” is pressed, all indicators for data are blinking. Then, if pressing “Set”, the data is fixed. (Setting range:0 * 10 6553 * 10 hours) The indicator changes from blinking to flashing continuously. Ex) 65530 hours/ 10 3-15 3 TROUBLE DIAGNOSIS AND REPAIR 50 51 52 53 ●Engine on/off count (50) ●Starter on/off count (51) ●Compressor R on/off count (52) ●Compressor L on/off count (53) ○Check mode The present on/off number is flashing Ex) Engine on/off count is 0. When pressing “Set”, each place is blinking from large to small place, 1000 → 100 → 10 → 1. If pressing “Code no. UP”, the number changes from small to large, like 0→…→9→0→…→9. If pressing “Code no. DOWN”, the number changes from large to small, like 9→…→0 →9→…→0 If pressing “Set” when one’s place is blinking, all data is blinking. Then, if pressing “Set”, the data is fixed. (Setting range: 0 to 9999 /100 times) The data indicator changes from blinking to flashing continuously. Ex ) 123400 / 100 times 56 57 ●Periodic inspection reset ●Automatic address erase ○Check Mode Displayed “OFF” ↓ Press “Set” Displayed “Go” ↓ Press “Set” in more 2 seconds or more to fix the indication Displaying “End” 58 59 Note: Power off after automatic address erase If not power off, error (E1) will happen. ●Main Microcomputer Version ●Engine Microcomputer Version ○Monitor Mode Ex Engine Micro Computer version… Ver.1. 10 3-16 AISIN Aisin gas heat pump 60 ●Pressure displayed ○Monitor Mode Ex High pressure …0.68 MPa 63 76 80 99 ●Temperature displayed ○Monitor mode Ex 1-2 pin temperature … ●Indoor unit and periphery Ex When connecting indoor unit no. ○In not selecting indoor unit Ex Indoor unit 3 Displaying indoor unit intake temperature (11 ) ↓ ↑every 2 seconds Displaying Code no. and indoor unit address alternately. ○In selecting indoor unit monitor mode is displayed Ex) Displaying the indoor unit intake temperature of Indoor unit 11(2 ) ↓ Pushing “Indoor unit select” Ex) Display indoor unit intake temperature of Indoor unit address 45 (18 ) ↓ Pushing “Indoor unit select” When the number is more than the number of connected indoor units, the indoor unit address returns to the minimum number address. ○In selecting indoor unit, command mode and check mode Ex Connecting 2 sets of indoor units Ex.)Display the operation status (Stop) of indoor unit address 11. ↓ Pushing “Indoor unit select” Ex Display the operation status of indoor unit 45 (Air ventilating) ↓ Pushing “indoor unit select” Select all sets of the connected indoor units. Display the operation status of the minimum number of indoor unit. ↓ Pushing “indoor unit select” 3-17 3 TROUBLE DIAGNOSIS AND REPAIR When the number is more than the number of connected indoor units, the indoor unit address returns to the minimum number address. 94 ●Indoor unit expansion valve angle ○Check mode In pressing “Set”, “Jido” is flashing. When “Jido” is blinking, pressing both “Code no. UP” and “Code no. DOWN” The present oil return condition is blinking. Ex) Oil return is OFF. When pressing “Code no. UP”, the oil return is ON. When pressing “Code no. DOWN”, the oil return is OFF. When pressing both “Code no. UP” and “Code no. DOWN”, “Jido” is blinking. When pressing “Set”, the display is fixed (Setting range: ON / OFF) The display changes from blinking to flashing continuously. Ex) Oil return is ON. 3-18 AISIN Aisin gas heat pump 95 ●Display of indoor unit capacity ○Monitor mode ex) Indoor unit capacity J280 (28.0 kw) ex) Indoor unit capacity J28 (2.8 kw) 3-19 3 TROUBLE DIAGNOSIS AND REPAIR 99 ●Indoor unit operation condition ○Command mode Operation condition of selected indoor unit address is blinking. Ex) When the selected indoor unit is stopped. When pressing “Set”, the hundred’s place is blinking. When the hundred’s place is blinking if “Code no.UP” is pressed, li →F→J→C→H If “Code no. DOWN” is pressed, H→C→J→F→ When “Set” is pressed, the value is blinking. Ex) Heating setting When the value is blinking, if “Code no. UP” is pressed, the value changes from small to large number like18→ 19 → … → 30 → cr. If “Code no. DOWN” is pressed, the value changes from large to small number like cr → 30 → … → 19 → 18. If press “Set” , all data is blinking. Then, pressing “set”, the value is fixed. The display of data changes from blinking to flashing continuously. Ex) heating mode, set temp. 30 Display of Indoor unit operation condition (data) is following. Ex) Cooling, set temp. 19 setting --- C19 Heating, set temp. 30 setting --- H30 Dehumidify , set temp 18 setting --- J18 Ventilation Setting --- F - Stop Setting --- - - Cooling test operation Setting --- Ccr Heating test operation Setting --- Hcr Range of set temperature… 18 to 30 In cooling test operation, the set temperature is the present target temperature which is set presently. 3-20 AISIN Aisin gas heat pump 3.2 Trouble Items and Diagnosis 3.2.1 Error Codes, Contents, and Major Likely Causes Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy E1 1 0 Communication error between the indoor unit and the remote control unit 1) Power-off of some specific indoor units during multiple indoor unit control from one remote control unit 2) Incomplete contact or wire disconnections of the remote control unit signal line (white) 3) Noise in the remote control cable 4) Indoor unit circuit board fault (CPU uncontrollable) 1) Measure the supply voltage at the power terminal block of the indoor unit. 2) Confirm power W, the power fuses, and the power transformer. 3) Confirm the electrical continuity, insulation, and polarity of the remote control signal line. 4) Confirm the color and voltage of the remote control signal line (black or red, 10 VDC). 5) Cut off the noise induction route and/or shield the remote control cable. 6) If the abnormality cannot be corrected even by resetting the power system, confirm the circuit board of the indoor unit. E2 2 0 Indoor unit address number overlapping 1) Indoor unit address number overlapping Pairing error 1) The outdoor unit is powered off or the CPU on the circuit board of the outdoor unit is uncontrollable. 2) The network signal line of the outdoor unit is not connected properly or is disconnected. 3) The machine number of the outdoor unit is not set properly (an outdoor unit having the same machine number as that of the indoor unit is not present). 4) The circuit board of the outdoor unit is abnormal. 5) The outdoor unit is powered off or the CPU on the circuit board of the outdoor unit is uncontrollable. 6) The address number of the outdoor unit is not set properly. 1) Confirm the address number settings of the indoor unit (indoor unit address Nos. U0 to U47 must be free from overlapping). 1) Measure the supply voltage at the power terminal block of the outdoor unit. 2) Confirm power W, the power fuses, the power transformer, the power circuit board, and the outdoor unit circuit board. 3) Check if the outdoor signal lines are connected properly. 4) Check and, if necessary, correct the assigned indoor and outdoor unit address numbers. 5) Check and, if necessary, correct the assigned outdoor unit address numbers. E3 — 3-21 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode — 5 0 — 50 0 E5 — Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy Communication error between the indoor and outdoor units 1) Improper connection of the outdoor unit signal line during operation (disconnected or loosened) 2) Communication error between the outdoor and indoor units due to noise or others 3) Power-off (interruption or out-of-phase) during the operation of the indoor and outdoor units driven by independent power supplies 4) Power supply cable disconnection of the outdoor unit circuit board or outdoor unit circuit board fault 5) Outdoor unit circuit board fault (the outdoor unit circuit board or CPU has become abnormal during the operation of the power supply) 1) Check for improper outdoor and indoor unit signal line connections. 2) Check the wiring route. 3) Shield the indoor and outdoor unit signal lines. 4) Measure the supply voltage at the power terminal block of the indoor and outdoor unit. 5) Confirm power W, the power fuses, the power transformer, the power circuit board, and the outdoor unit circuit board. 6) Check the outdoor unit circuit board. E6 96 ? Indoor heat exchanger temperature sensor wire disconnections 1) Indoor heat exchanger temperature sensor malfunction (defective element, wire disconnections) 2) Improper connection of the sensor connector 3) Indoor unit circuit board fault (heat exchanger sensor input circuit fault) 1) Confirm the connection of the indoor heat exchanger temperature sensor and sensor connector. 2) Confirm temperature display and compare an actual temperature value and the resistance value. 3) Check the indoor unit circuit board. E7 97 ? Indoor intake temperature sensor wire disconnections 1) Indoor intake temperature sensor malfunction (defective element, wire disconnections) 2) Improper connection of the sensor connector 3) Indoor unit circuit board fault (sensor input circuit fault) 1) Confirm the connection of the indoor intake temperature sensor and sensor connector. 2) Confirm temperature display and compare an actual temperature value and the resistance value. 3) Check the indoor unit circuit board. E9 95 ? Indoor unit drain water alarm 1) Check the drain piping. 2) Float switch malfunction 3) Drain pump fault, drain pump wire or connector disconnections 1) Check the pipe installation angle and start-up dimensions. 2) Check the float switch, float switch harness, and connectors (continuity: normal) 3) Check the drain piping. E12 — Addressing alarm 1) Mismatching of the address switch settings 1) For details refer to “3.1.2 Details of Address Setting Errors 1.2”. E28 — Remote control unit intake temperature sensor wire disconnections 1) Remote control unit sensor wire disconnections 1) Check the remote control unit sensor. 3-22 AISIN Aisin gas heat pump Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy E43 43 0 Too many indoor units connected 13 indoor units or more are connected to one outdoor unit 1) 8-PS building-use multi-type: 13 units or more 2) 10-PS building-use multi-type: 13 units or more 3) 13-PS building-use multi-type: 13 units or more Reviewing the number of indoor units which are connected 1) 8-PS building-use multi-type: 12 units or less 2) 10-PS building-use multi-type: 12 units or less 3) 13-PS building-use multi-type: 12 units or less E56 94 ? Indoor heat exchanger temperature sensor short-circuiting 1) Indoor heat exchanger temperature sensor fault or short-circuiting 2) Harness short-circuiting 1) Confirm temperature display using the maintenance board. 2) Check if the indoor heat exchanger temperature sensor and related harness are short-circuited. E31 31 0 Outdoor unit address overlapping — 4 0 Outdoor unit address number setting error 1) Outdoor unit address overlapping (U0 to U47) 2) Outdoor unit address number setting error 1) Check and, if necessary, correct the assigned outdoor unit addresses. 2) Check and, if necessary, correct the assigned outdoor unit address numbers. E34 41 1 Less phase error 1) T phase of three-phase power supply is disconnected. 1) Check the power supply wiring. 2) Check setting of power supply 2) Mistaken power supply (sub-circuit connector) — 41 — E36 1 2 Power supply connection error - 1) In connection of three-phase power supply, the setting of power supply on the sub-circuit board is single. 1) Reconnect the connector. 91 0 Excessive increase in compressor air discharge temperature 1) Shortage of refrigerant, refrigerant flow channel clogging, compressor compression error 2) Improper heat release from condensing unit 3) Entry of non-condensed gas 1) Confirm the pipe temperature and pressure of the refrigerant system. 2) Confirm the amount of refrigerant (discharge temperature, refrigerant high-pressure value, and refrigerant low-pressure value). 3) Check the air filter for clogging in heating mode. 4) Confirm the operation of the hot-gas bypass valve, oil returning bypass valve, and four-way valve. 91 2 91 3 Compressor air discharge temperature sensor alarm 1) Discharge temperature sensor fault or harness short-circuiting 1) Confirm temperature display using the maintenance board. 2) Check the discharge temperature sensor harness for short-circuiting. 3) Check the discharge temperature sensor connectors. 3-23 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode E38 E39 E40 E52 E53 E54 Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy 1) Outside air temperature sensor fault, wire disconnections, or improper connector connections 2) Outside air temperature sensor fault or short-circuiting 1) Check the temperature display. 2) Check the outside air temperature sensor and connector connections. Compressor discharge temperature sensor wire disconnections 1) Discharge temperature sensor fault, wire disconnections or improper connector connections 1) Check the temperature display. 2) Check the discharge temperature sensor and connector connections. 0 Refrigerant high-pressure switch wire disconnections 1) High-pressure switch malfunction 2) Harness wire disconnections or improper connector connections 1) Check the refrigerant high-pressure switch. 2) Confirm harness continuity and connector connections. 86 0 Refrigerant high-pressure alarm 1) Improper heat release from condensing unit 2) Refrigerant circuit malfunction (such as a blocked or overfilled status) 1) Check for clogging of the heat exchanger near the condenser, and for abnormal operation of the fan. 2) Check the refrigerant system (check for refrigerant leakage, clogging, etc.) using refrigerant system diagrams A, B, D, and Q. 72 0 Engine room temperature sensor wire disconnections 72 1 Engine room temperature sensor short-circuiting 1) Engine room temperature sensor fault, or improper connector connections 2) Engine room temperature sensor fault or short-circuiting 3) Discharge temperature sensor fault or improper connector connections 72 6 Exhaust air temperature sensor disconnections 1) Confirm temperature display (compare an actual temperature value and the resistance value). 2) Confirm engine room temperature sensor and connector connections. 3) Confirm exhaust temperature sensor and connector connections. 53 0 Compressor intake temperature sensor wire disconnections 53 2 Compressor intake temperature sensor short-circuiting 1) Compressor intake temperature sensor fault 2) Compressor intake temperature sensor harness wire disconnections 3) Improper connector connections 4) Compressor intake temperature sensor harness short-circuiting 1) Confirm temperature display using the maintenance board. 2) Check for the harness wire disconnections. 3) Check for improper connector connections. 4) Check for harness short-circuiting. 63 0 Accumulator inlet temperature sensor wire disconnections 63 1 Accumulator inlet temperature sensor short-circuiting 1) Accumulator inlet temperature sensor fault, wire disconnections, or improper connector connections 2) Accumulator inlet temperature sensor fault or short-circuiting 1) Confirm temperature display (compare an actual temperature value and the resistance value). 2) Confirm the accumulator inlet temperature sensor and connector connections. 61 1 Outside air temperature sensor wire disconnections 61 0 Outside air temperature sensor short-circuiting 78 0 78 1 76 3-24 AISIN Aisin gas heat pump Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy 1) Gas pipe temperature sensor fault, wire disconnections, or improper connector connections 2) Gas pipe temperature sensor fault or short-circuiting 1) Confirm temperature display (compare an actual temperature value and the resistance value). 2) Confirm gas pipe temperature sensor and connector connections. 64 0 Gas pipe temperature sensor wire disconnections 64 1 Gas pipe temperature sensor short-circuiting 88 0 Refrigerant low-pressure alarm 1) Improper heat release from evaporator unit 2) Refrigerant circuit malfunction (such as a blocked or overfilled status) 1) Check for clogging of the heat exchanger near the evaporator, and for abnormal operation of the fan. 2) Check the refrigerant system (check for refrigerant leakage, clogging, etc.) using refrigerant system diagrams A, B, D, and Q. 88 2 Refrigerant low-pressure switch wire disconnections 1) Low-pressure switch malfunction 2) Harness disconnections or connector disconnections 1) Check the refrigerant low-pressure switch. 2) Confirm harness continuity and connector connections. 88 5 No refrigerant 1) Refrigerant leakage 2) Malfunction of pressure sensor or low-pressure switch E58 47 0 Exhaust temperature alarm 1) Refrigerant leakage from the flare connection and others 2) Pressure sensor malfunction 1) Deodorization agent clogging E80 80 0 Engine coolant too hot 80 1 Engine coolant temperature sensor wire disconnections 80 2 No engine coolant E55 E57 1) 2) 3) 4) Coolant circulation error Heat release insufficient Sensor malfunction Short-circuiting due to contact of the coolant sensor harness with the body 5) No-load operation without added coolant 1) Check the deodorization agent 1) Check if the coolant level in the reservoir tank is between F and L. Also, check the thermostats and the thermovalves. 2) Confirm the temperature differences between A-B and C-D connections per the coolant system diagram (Cooling: 7 to 10 °C, Heating: 10 to 15 °C). 3) Check for clogging of the radiator and for abnormal operation of the coolant pump and outdoor unit fan. 4) Check the coolant temperature sensor. 5) Check the harness connector. E81 81 0 Engine oil pressure alarm 1) Oil pressure too low (or oil level too low or others) 1) Check the oil level (the oil level must be between F and L on the oil level gauge). 2) Check the oil pressure switch and harness. E82 82 0 82 1 Engine speed too high alarm 1) Stepping motor malfunction or others 1) Confirm the stepping motor coil resistance value. 2) Check connector and harness connections. 3-25 3 TROUBLE DIAGNOSIS AND REPAIR Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode E83 60 0 Diagnosis and Repair Contents Major Likely Causes Starter alarm 1) Fusing of the starter driving relay inside the control box 2) Outdoor unit circuit board malfunction 74 1 Engine starting speed alarm 1) Starting motor malfunction 2) Connector disconnections 3) Pickup coil wire disconnections 74 4 Engine speed control alarm 1) Connector disconnections Diagnosis/Remedy 1) Confirm whether, when the starter is turned off, 12 VDC is applied to the starter pinion coil. 2) Confirm whether, when the starter is turned off, 12 VDC is applied to the starter driving relay. 1) Check the starting motor. 2) Check the starting motor, pinion connector, and pinion harness. 3) Check the pickup coil. 4) Check the outdoor unit circuit board. 1) Make sure that connector CN10 (l) is not disconnected. 2) Make sure that connector CN33 (X) is not disconnected. 3) Check the outdoor unit circuit board. 74 7 Gas electromagnetic valve output alarm 1) Gas electromagnetic valve output error 1) Check the outdoor unit circuit board. 84 0 Engine start alarm 75 0 Engine stop 1) Fuel circuit malfunction 2) Ignition circuit malfunction 3) Improper compression 1) Check the gas-operated solenoid valve and the regulator. 2) Check the ignition plugs (plug gap: 0.4 to 0.1 mm) and the high-tension cords. 3) Confirm compression (at least 12.0 kg/cm2) and check the O2 level. 4) Check the clearances (INO. 35 mm, EXO. 0.35 mm). E85 44 ? Indoor unit mismatch 1) Insufficiency in engine output 2) Stepping motor malfunction or others E86 71 0 Engine oil pressure switch wire disconnections 1) Oil pressure switch malfunction 2) Harness wire disconnections or connector disconnections 1) Confirm compression (at least 11.0 kg/cm2) and check the O2 level. 2) Check the stepping motor. 1) Check the oil pressure switch. 2) Confirm harness continuity and connector connections. 3) Confirm that the output of the starter capacitor is 12 V (if necessary, retighten the plus and minus terminals). E87 70 0 Engine coolant temperature sensor wire disconnections 1) Engine coolant temperature sensor wire disconnections 2) Harness wire disconnections or connector disconnections 1) Check the coolant temperature sensor. 2) Confirm harness continuity and connector connections. — 74 6 Engine speed hunting alarm 1) Engine speed hunting alarm — 84 3 Engine microcomputer communications error 1) Engine microcomputer communications error 1) Check the fuel gas pressure. 2) Check the engine speed sensor. 3) Check the engine speed sensor for improper contact 4) Check the outdoor unit circuit board. 1) Check the outdoor unit circuit board. E84 3-26 AISIN Aisin gas heat pump Alarm Code Maintenance Display of Board Remote Control Unit Code SubCode Diagnosis and Repair Contents Major Likely Causes Diagnosis/Remedy — 84 4 Engine program writing alarm 1) Engine program writing error 1) Check the outdoor unit circuit board. E89 65 0 Outdoor heat exchanger liquid temperature sensor wire disconnections 1) Outdoor heat exchanger liquid temperature sensor malfunction, wire disconnections or improper connector connections 1) Confirm temperature display using the maintenance board. 2) Check the outdoor heat exchanger liquid temperature sensor for wire disconnections and improper connections. 65 2 Outdoor heat exchanger liquid temperature sensor short-circuiting 1) Outdoor heat exchanger liquid temperature sensor malfunction or short-circuiting 1) Confirm temperature display using the maintenance board. 2) Check the outdoor heat exchanger liquid temperature sensor and harness short-circuiting. 73 0 Refrigerant high-pressure sensor alarm 1) High-pressure sensor malfunction or short-circuiting 1) Confirm pressure display using the maintenance board. 2) Check the high-pressure sensor and harness short-circuiting. 73 1 1) High-pressure sensor malfunction, cord disconnections or connector disconnections 1) Confirm pressure display using the maintenance board. 2) Check for wire disconnections of the high-pressure sensor and harness and for improper connections of the connector. 87 0 Abnormal increase in compressor intake temperature 1) Four-way changeover valve stalled in the middle 2) Hot-gas bypass valve malfunction 1) Check the temperatures of the four-way changeover valve and periphery. 2) Check the operation of the hot-gas bypass valve. — 70 5 Fault in motor-driven three-way valve hole IC 1) Fault in motor-driven three-way valve hole IC 1) Check the output of the motor-driven three-way valve hole IC. 2) Check for wire disconnections and improper contact of the harness. 3) Check the outdoor unit circuit board. — 40 0 EEPROM error 1) EEPROM error 1) Check the outdoor unit circuit board. — 3 0 Indoor unit not connected 1) The setting of the outdoor unit address at the indoor unit side is not correct. 2) Despite the indoor/outdoor unit independent power specifications, the indoor unit is powered off. 1) Confirm and review the setting of the addressing switch. 2) Perform indoor unit power checks and reviews. E61 93 ? Mode mismatch Mode mismatch 1) Check the setting of the remote-controlled operation mode. 3-27 3 TROUBLE DIAGNOSIS AND REPAIR Details of Address Setting Errors (1.2) Type or Addressing Outdoor Unit Switch (Outdoor No.) Automatic 49 Manual 0 to 48 By remote control unit 0 to 48 Indoor Unit Switch Alarm Display Address Setting Status Outdoor No. Indoor No. Code Unit 49, 48 0 to 47 E12 U49 0 to 47 0 to 47 E3, E46 U0 to U47 0 to 47 49, 48 E12 U49 Addressing error 0 to 47 49, 48 E12 U49 Addressing error 49, 48 0 to 47 E12 U49 Addressing error 49, 48 49, 48 — — Addressing error Pairing error Not to be used Notes: 1. Automatic addressing settings are not stored into memory when E12 is displayed. 2. E3 is displayed for the indoor units whose automatic address settings have already been stored into memory. 3. The unit numbers listed above are for reference only. 3-28 AISIN Aisin gas heat pump 3. 3 Diagnostic Items Section To Be Measured Check Item Power circuit breaker (ELB) Red - White 1 2 Power terminal (TB1) Red - White R S Normal Voltage Normal Resistance Remarks 200 VAC Outdoor unit circuit CN18 - 1 (Red) board - 2 (White) Ventilation fan (EFAN) CN14 - 3 (White) - 10 (Black) 200 VAC 170 Ω Fan motors 1 and 2 (FM1, FM2) Fan 1: CN13-2, 7 200 VAC Single-speed type (FM1) White-Black 24.6Ω±10% Black-Yellow 60.9Ω±10% Two-speed type (FM2) White-Black 24.6Ω±10% Orange-Red 35.2Ω±10% Red-Black 27.5Ω±10% Outside air temperature sensor (THO) CN6 - 15, 16 (White) Engine room temperature sensor (E/GR) CN6 - 13, 14 (Red) Throttle valve (STM) CN11-9 to 14 Pulse waveform at –30 to + 30 VDC Engine oil pressure switch (OLP) CN8 Brown - Yellow 17 18 Gas electromagnetic valve 1 (GV1) CN7 White - White 19 20 Gas electromagnetic valve 2 (GV2) CN7 Black - Black 17 18 Starter (STR) Motor plus terminal Ground 11 - 19 VDC Starter pinion coil Starter relay output terminal or starter pinion terminal Ground 11 - 13 VDC Digital igniter (controller) (IGN) IGN-H, C 12 VDC Fuel gas regulating valve (FUEL) CN11 - 3 (Yellow) - 1 (White) - 5 (Orange) - 4 (Red) - 7 (Blue) - 6 (Red) –30 to +30 VDC Engine Main unit Fan 2: CN13-3, 4, 8 Coolant heater CN13 - 1, 6 (Blue) (E/G WH) (Option) –20°C....... 39.58 kΩ –10°C....... 23.95 kΩ 0°C........ 15.00 kΩ 10°C ....... 9.58 kΩ 20°C ....... 6.43 kΩ 30°C ....... 4.21 kΩ 40°C ....... 3.04 kΩ - Unconnected wire detection temperature below –39°C is detected continuously for one min. (Outside air temperature sensor wire disconnections: E38) (Engine room temperature sensor wire disconnections: E52) ON: 1 VDC or less OFF: 11 - 13 VDC 1 Ω or less 1 MΩ or more The oil pressure is abnormal for three sec or more. 10 - 16 VDC (14 VAC full-wave rectification) 21 Ω B1 - S1 B1 - S3 B2 - S2 B2 - S4 S1 - S3 S2 - S4 32 ± 2 Ω 64 ± 4 Ω S4 B2 S2 S3 B1 S1 160 Ω ± 12 Ω 200 AVC 3-29 - Short-circuiting detection temperature above 90°C is detected continuously for one min. (Outside air temperature sensor short-circuiting: E38) (Engine room temperature sensor short-circuiting: E52) TROUBLE DIAGNOSIS AND REPAIR Section To Be Measured Check Item Normal Voltage Exhaust temperature sensor (E/G E) (Option) CN7 - 13, 14 (Yellow) Outboard 12-V power supply CN26 - 1 (Red) - 2 (Black) 12 VDC Exhaust drain heater (DH) (Only for Winterized type) CN14 - 13 (Black) - 7 (White) 200 VAC Coolant temperature sensor (WT) CN7 Normal Resistance Remarks Engine (Room temp.) .................... Continuity 200°C.......... 371100 Ω 300°C.......... 52600 Ω 400°C.......... 11500 Ω 500°C.......... 3529 Ω 600°C.......... 1378 Ω 700°C.......... 637.6 Ω 800°C.......... 342.0 Ω 1.33 kΩ ± 15% 50°C ....... 17.6 kΩ 80°C ....... 6.1 kΩ 100°C....... 3.3 kΩ 110°C....... 2.5 kΩ - 9 (Black) - 12 (White) - Coolant temperature of 105°C or more is detected for 10sec (Abnormal engine coolant temperature: System shutdown) Coolant circuits - Coolant temperature below 0°C is detected for three min when Engine RPM is 700rpn or more. during operation. (Engine coolant temperature sensor wire disconnections: System shutdown) Coolant pump (WP) CN13 - 5 (Black) - 9 (White) 200 VAC 58.4 kΩ ± 10% Motor-driven three-way valve (EWV) CN10 - 9 (Brown) - 10 (Black) - 11 (Blue) - 13 (Orange) - 14 (White) - 15 (Yellow) 11 to 13 VDC Brown - White Orange - White Blue - White Yellow - White CN8 Discharge temperature sensors R and L (C/P TR) (C/P TL) High-pressure switch (HL SW) Refrigerant circuits 3 - 5 (Green) - 6 (Red) 0°C........ 182.9 kΩ 20°C ....... 70.4 kΩ 50°C ....... 20.2 kΩ 80°C ....... 7.0 kΩ 100°C....... 3.7 kΩ 120°C....... 2.1 kΩ R: CN6 - 7, 8 L: CN6 - 5, 6 CN8 36 Ω 36 Ω 36 Ω 36 Ω - 3 (Black) - 4 (Black) OFF: 11 - 13 VDC 1 MΩ or more ON: 1 VDC or less 1 Ω or less - Wire disconnection detection temperature below 5°C is detected for ten min. (Discharge temperature sensor wire disconnections: E39) - Short-circuiting temperature above 120°C is detected for one min. (Discharge temperature sensor short-circuiting: E36) - Error detection at a high pressure of 2.75 MPa (OFF) - Return to normal at 2.16 MPa (ON) High-pressure sensor (HS) CN7 - 8 (Red) - 4 (Black) 5 VDC ± 0.5 V Output voltage CN7 White - Black 3 4 (MPa) 3.0 2.0 1.0 0 0.5 1 2 3 3.5 Output voltage (V) The output voltage value is about 1 V for 1 MPa. Low-pressure switch (LLSW) CN8 - 1 (Black) - 2 (Black) OFF: 11 - 13 VDC 1 MΩ or more ON: 1 VDC or less 1 Ω or less - Error detection at a low pressure of 0.05 MPa (OFF) - Return to normal at 0.15 MPa (ON) 3-30 AISIN Aisin gas heat pump Section To Be Measured Check Item Normal Voltage CN10 - 1 (White) - 2 (Red) - 3 (Yellow) - 4 (Brown) - 5 (Orange) - 7 (Blue) 11 - 13 VDC Oil returning valves 1 and 2 (OILB1) (OILB2) 1: CN15 - 9 (Red) - 17 (Red) 200 VAC Heat exchanger liquid temperature sensor (THL) CN6 - 1, 2 (White) Gas pipe temperature sensor (GAS) CN6 - 9, 10 (White) Liquid flow regulating valve (EV1) (Electronic expansion valve) Normal Resistance Remarks Red - White (5-6) Red - Orange (5-3) Brown - Yellow (2-4) Brown - Blue (2-1) ......... 150 Ω ± 10% White - Orange (6-3) Yellow - Blue (4-1) Refrigerant circuits ......... 300 Ω ± 20% 1.2 kΩ 2: CN15 - 8 (Purple) - 16 (Purple) –10°C.... 24.0 kΩ 0°C..... 15.0 kΩ 10°C .... 9.7 kΩ 20°C .... 6.4 kΩ 30°C .... 4.3 kΩ 40°C .... 3.0 kΩ 50°C .... 2.2 kΩ 55°C .... 1.83 kΩ 60°C .... 1.56 kΩ 65°C .... 1.34 kΩ 70°C .... 1.15 kΩ 75°C .... 0.99 kΩ Intake temperature CN6 sensor (C/P SR) - 11, 12 (White) Accumulator inlet temperature sensor (AIN) CN6 - 3, 4 (White) Hot gas bypass valve (BV) CN14 - 1, 8 (Purple) 200 VAC 800 Ω Compressor clutches R and L (C/P R, C/P L) R: CN12-2 11 - 13 VDC 4 Ω ± 20% Four-way changeover valve (4PV) CN15 - 2, 11 (Black) 200 VAC 1.3 kΩ ± 20% Capacity regulating valve (C/P FV) CN10 - 17 (White) - 18 (Red) - 19 (Yellow) - 20 (Brown) - 21 (Orange) - 23 (Blue) 11 - 13 VDC Red - White (5-6) Red - Orange (5-3) Brown - Yellow (2-4) Brown - Blue (2-1) ......... 150 Ω ± 10% - Wire disconnection alarm when temperature of less than –39°C is detected continuously for one min. - Short-circuiting alarm when temperature of 90°C or more is detected continuously for one min. - Alarm codes for short-circuiting: E37, E55, E54 L: CN12-1 White - Orange (6-3) Yellow - Blue (4-1) Indoor unit circuits ......... 300 Ω ± 20% Indoor unit temperature sensor (THI-A) On indoor unit circuit board CNH 1 - 2 Indoor heat exchanger temperature sensor (THI-R) CNH 3 - 4 Float switch (FS) FASTON terminal 9-5 (On indoor unit circuit board) –10°C....... 29.1 kΩ 0°C........ 16.8 kΩ 10°C ....... 10.8 kΩ 20°C ....... 6.2 kΩ 30°C ....... 4.0 kΩ 40°C ....... 2.6 kΩ 50°C ....... 1.8 kΩ OFF: 200 VAC ON: 10 VAC or less 3-31 - Unconnected jumper detection temperature (–40°C) is detected continuously for 5 sec. (Indoor unit temperature sensor wire disconnections: E7) - Unconnected jumper detection temperature (–40°C) is detected continuously for 5 sec. (Indoor heat exchanger sensor disconnections: E6) - Drain pump is operated - Float switch OFF is detected - Compressor ON in cooling and dehumidifying (operated for 2min after compressor off ) 3 TROUBLE DIAGNOSIS AND REPAIR 3.4 Trouble Diagnosis and Check 3.4.1 If the System Does Not Operate Classification of Likely Causes Trouble The system does not operate. No data is displayed on the panel of the remote control unit. 1) Faults in the power circuits Sub-Classification Check and Remedy - Incorrect power line wiring - Wire disconnections or incomplete contact - See “(1) Checking the power circuits”. - Control circuit fault - Tripped ground leakage circuit breaker - Wire disconnections or 2) Faults in the incomplete contact remote control circuit - Fault in the remote control unit 3) Faults in the Data is displayed - Incorrect communications line communications wiring on the panel of the remote control circuit - Wire disconnections or unit, but the incomplete contact system does not - Incorrect DIP switch settings operate. - Incorrect wiring - Wire disconnections or incomplete contact - Control circuit fault - See “(4) Checking the remote control circuit”. - Check the communications lines for disconnections and internal short-circuiting. - See “(5) Checking the DIP switches”. - See “(2) Checking the control section”. Y Y Bl Bl Bk W W Outdoor unit circuit board Br - See “(2) Checking the control section”. - See “(3) Diagnosing for current leakage”. G R Or Y Bl Br Bl (Single phase) (Three phase) I.U (1) Checking the power circuits [1] Check that the power lines of the indoor and outdoor units are connected properly in accordance with the installation manual. [2] Check that a supply voltage of 200 VAC is applied to the power terminals of the indoor and outdoor units. (2) Checking the control section [1] Outdoor unit If the green LED on the circuit board does not blink in spite of 200 VAC being applied, the power transformer or the power board is likely to be malfunctioning. Confirm the input and output voltages. [2] Indoor unit Similarly, confirm the input and output voltages of the indoor unit transformer as well. If 200 VAC is not applied, there may be a broken fuse(s). Red White 200 V 8V Red Blue 17 V White Blue 3-32 AISIN Aisin gas heat pump (3) Diagnosing for current leakage If the ground leakage circuit breaker trips, measure insulation resistance values using a megohmmeter and diagnose for current leakage. Leakage diagnosing procedure [1] Checking the 200-V units If the resistance value can be recovered by disconnecting the CN1, CN2, and CN4 connectors from the outdoor unit circuit board, current is leaking from either of these connections. Check each unit independently. Example of DIP switch setting Indoor unit address Refrigerant piping Communication cable Outdoor unit Outdoor unit address Indoor unit No.1 Remote control unit SW1 SW2 [2] Checking the indoor units If the resistance value can be recovered by disconnecting the power terminals from the terminal blocks of each indoor unit, current is leaking from either indoor unit. Note: Do not connect the megohmmeter communications circuits. to the Indoor unit No.2 Remote control unit (4) Checking the remote control circuit Check the terminals of the indoor units and remote control unit for incomplete electrical contact and for wire disconnections. (5) Checking the DIP switches Check the DIP switches of the indoor and outdoor units and remote control unit for incorrect settings. Indoor unit No. Indoor unit No.10 Remote control unit Outdoor unit No. Setting of the slide switch of the remote control unit Sub SW4 Outdoor unit No. setting Indoor unit No. setting Main 3-33 3 TROUBLE DIAGNOSIS AND REPAIR 3.4.2 If the Starter Does Not Operate Classification of Likely Causes Trouble E83 (74) display Engine starting failure The starter does not operate. Sub-Classification Check and Remedy - See “(1) Checking the starter”. [1] Starter pinion does not operate Pinion driving coil malfunction No output [2] Starting motor and pinion do not operate Starting motor malfunction No output The starter driving circuit is likely to be malfunctioning if neither the pinion coil nor the starting motor develops an output voltage. [3] Starter driving circuit malfunction Transformer Relay malfunction - See “(2) Checking the transformer”. - See “(3) Checking relays for normal operation”. (1) Checking the starter [1] Checking the output voltage to the starter – Output voltage to the starting motor Check that an output voltage of 12 VDC is applied between the terminal B and body of the starting motor during the operation of the ventilation fan. – Output voltage to the pinion driving coil Check that when the starting motor lamp on the maintenance board is on, an output voltage of 12 VDC is applied between the terminal S and body of the starting motor. Terminal S Terminal B Terminal M [2] Checking the starter Measuring Sections Reference Resistance Value at 20°C Terminal S – Body ground 0.24 Ω Terminal B – Body ground ∞ Terminal M – Body ground 0.01 Ω Terminal S – Terminal M 0.24 Ω Terminal S – Terminal B ∞ Terminal B – Terminal M ∞ (2) Checking the transformer [1] Checking the secondary output voltage Check that an output voltage of 12 VAC is applied between the primary terminal of the diode and the frame ground during the operation of both the ventilation fan and the coolant pump and stoppage of the starter. [2] Checking the primary input power Check that a voltage of 200 VAC is applied during the operation of both the ventilation fan and the coolant pump. The transformer may be malfunctioning if, despite the primary input voltage being normal, the secondary output voltage is abnormal. [3] Checking the transformer unit Check for primary/secondary coil disconnections and for internal short-circuiting. 3-34 AISIN Aisin gas heat pump (3) Checking relays for normal operation (See the reference diagram below.) [1] Relay R-1 turns on at the same time the motor becomes ready for operation (the coolant pump and the ventilation fan start operating). Therefore, make sure at this time that 12 VDC is applied between terminals 1 and 2. Also, check the relay coil and verify electrical continuity between terminals 1 and 2. [2] Relay R-3 turns on during the start of the starter. Make sure that 12 VDC is applied between terminals 1 and 2 during starter start. Also, check the relay coil and verify electrical continuity between terminals 1 and 2. Starting motor driving circuits (Reference diagram) Bl Y R W R Or Y Y YY BlBl BkWW R W Bk R Bk W Br GrR OrY Control Box (Single phase) (Three phase) Bl: Blue, Y: Yellow, R: Red, W: White, Or: Orange, Bk: Black Gr: Green Description of operation (1) After the OPERATE switch has been turned on, 12 VDC is applied between CN22 connector terminals 1 and 2 on the control circuit board at the same time the ventilation fan and the coolant pump operate, and thus R-1 is activated. (2) When R-1 is turned on, 200 VAC is applied to the primary side of the transformer TR1. (3) After rectification between the secondary side of the transformer and the diodes, a voltage of 11 to 19 VDC is applied to the plus terminal of the starting motor. (4) 12 VDC is output from the CN21 connector terminals 1 and 2 on the control circuit board, then R-3 is turned on, and 11 to 13 VDC is applied to the starter pinion coil to activate the starter. 3-35 3 TROUBLE DIAGNOSIS AND REPAIR 3.4.3 If the Engine Does Not Start Trouble E83 (74) display E84 (84) display Classification of Likely Causes 1) Intake/ exhaust circuit faults Engine starting failure Sub-Classification [1] Fuel gas Gas valve does not open Gas valve malfunction No output [2] Significant A-F ratio changes Air circuit Air intake port clogging Air cleaner clogging Fuel circuit Leakage from gas regulator Mixer malfunction Check and Remedy - See “(1) Checking the gas electromagnetic valves”. - Check and, if necessary, replace the air cleaner. - See “(2) Checking the gas regulator”. - Check and, if necessary, replace the mixer. See “(9) Mixer fuel valve check” and “(2) Checking the throttle actuator” in 3.3.4. 2) Ignition circuit faults [3] Exhaust circuit clogging Drain water freezing Drain hose freezing Exhaust heat exchanger or muffler clogging - Install a drain heater. [1] Plug malfunction Deposits or moisture Plug gap out of specs. - See “(3) Checking the ignition plugs”. [2] Ignition failure Cap or connector disconnections High-tension cord malfunction Igniter malfunction No output - See “(4) Checking the high-tension cords”. [3] Ignition timing error - See “(5) Checking the igniter”. - See “(1) Checking and adjusting ignition timing” in 3.3.4. Improper compression is likely if the crankshaft can be readily rotated by hand without resistance. 3) Compressor [1] Upward valve plunging circuit faults Valve clearance error - See “(6) Checking for appropriate compression”. - See “(7) Valve clearance check and adjustment”. [2] Valve caught in the mechanism 3-36 - See “(8) Improving incomplete compression due to an obstruction on the valve seat”. AISIN Aisin gas heat pump (1) Checking the gas electromagnetic valves [1] Checking the output voltage Check the maintenance board and the outdoor unit circuit board and make sure that an output voltage of 12 VDC is supplied. If, in spite of the fact that the corresponding LED is on during the check mode of the maintenance board, the required output voltage is not supplied, the switching circuit on the board is likely to be faulty. [2] Checking the gas electromagnetic valve body Disconnect the connector from the gas valve. Next, check the two electromagnetic valves for continuity between the respective terminals and scan for electromagnetic coil disconnections. Reference resistance value: 21 Ω (2) Checking the gas regulator Disconnect the fuel gas hose, then start the engine, and make sure that when the gas electromagnetic valves operate, the fuel gas does not leak from the gas regulator outlet pipe. If the fuel gas leaks, the gas regulator is malfunctioning. If gas injection from the inlet does not result in gas leakage and the gas is taken in smoothly from the outlet, the gas regulator is normal. Gas outlet Gas inlet Gas-operated solenoid valves (3) Checking the ignition plugs – Checking each ignition plug for sparking [1] Remove the ignition plug and close the main gas plug. [2] After inserting the ignition plug into the high-tension cord, bring the plug body into contact with the engine body. [3] Press the OPERATE switch and check that the engine will crank and that sparks will be generated. The above check can be performed by operating the starting motor alone for 5 seconds in the component check mode of the maintenance board. (Check mode: “31”) – Checking the ignition plug electrodes Check each plug for thermally or physically damaged, dirty, or unusually worn electrodes. Reference electrode gap: 0.4 to 1.0 mm Note: To remount the plug, hand-tighten it first and then retighten to a 20 to 25 Nxm torque using a plug wrench. (4) Checking the high-tension cords [1] Make sure that each high-tension cord is fully inserted. [2] Internal cord disconnections check Verify that the resistance values of the high-tension cord terminals are as listed below. #1 5.7 ± 2.2 #2 4.6 ± 1.8 #3 3.5 ± 1.3 kΩ 3-37 3 TROUBLE DIAGNOSIS AND REPAIR (5) Checking the igniter [1] Checking the output voltage of the igniter Make sure that the corresponding LED on the maintenance board is on and that an output voltage of 12 VDC is developed between the E1 (B) terminal and +B (A) terminal of the igniter. The above check can be performed by switching on the igniter alone for 3 minutes in the component check mode of the maintenance board. (Part code: “02”) Ignition coil assembly Cam shaft rotor Igniter assembly [2] Checking the ignition coils Check the primary and secondary disconnections and short-circuiting. ignition coils for Primary connector Reference resistance value: 2.8 Ω ± 10% (20°C) [3] Checking the cam angle sensor Confirm the resistance value between both terminals of the cam angle sensor. Resistance value: 1100 ± 150 Ω (20°C) (6) Checking for appropriate compression Measure the compression pressure of each cylinder using a compression pressure gauge to achieve the required engine output. The procedure is as follows: [1] Remove the ignition plug. [2] Insert and firmly screw down section 5 of adapter 4 into the plug hole. [3] Fully rotate section 3 in the direction of the arrow as far as 3 can go. The rubber piece of section 5 will be firmly pressed against the plug hole and fixed. [4] Mount a pressure gauge at a sufficient distance from all movable sections. [5] Crank the engine by pressing the OPERATE switch and measure the compression pressure of the cylinder. After selecting the check mode with the maintenance board functions and then turning on the transformer power, the above check can be performed by turning on the starter and letting it operate independently for 5 seconds. (Part code: “01”) [6] Reset the needle to zero by pressing section 1, and perform similar measurements for other cylinders as well. <Compression pressure gauge> Reference value: 1.4 MPa or more 3-38 AISIN Aisin gas heat pump (7) Valve clearance check and adjustment Top dead center mark [1] Remove the head cover. [2] Match the crank pulley to the top dead center mark as shown in the right view. [3] Make sure that when the crank pulley is rotated by about 20 degrees horizontally, the IN (intake) rocker arm of the #1 cylinder does not move. If the rocker arm moves, rotate the crank pulley through one full turn for matching to the top dead center. Front Rear #3 EX #3 IN #2 EX #2 IN #1 EX #1 IN [4] Loosen the adjust nuts on the #1 and #3 intake cylinders and the #1 and #2 exhaust cylinders as shown, and adjust each cylinder. [5] Rotate the crank pulley through 360 degrees. [6] Loosen the adjust nuts on the #2 intake cylinder and the #3 exhaust cylinder as shown, and adjust both cylinders. Reference Value 0.35 ± 0.05 mm Hot status 0.25 ± 0.05 mm Cold status Front IN IN EX Front EX (8) Improving incomplete compression due to an obstruction on the valve seat If carbon gets caught on the surface of the valve seat, clear this abnormal state by cleaning with a valve cleaner as follows: [1] Remove the ignition plugs and the air hose of the mixer. [2] Disconnect the igniter connectors from the control box. [3] Open the head cover, and rotate the crankshaft to where the clearances corresponding to the #1 and #3 IN cylinders can be adjusted. [4] Open the throttle valve of the mixer by an angle of 493 steps (fully open) using the maintenance function of the maintenance board. [5] Protect each plug hole with a waste cloth. [6] After injecting a valve cleaner from the hole in the mixer for about 20 seconds, leave the hole intact for about 10 minutes. [7] Manually rotate the engine pulley through one full turn. [8] Close the head cover, and crank the engine by activating the starter (use the maintenance function of the maintenance board). [9] Open the head cover, and rotate the crankshaft to where the clearance corresponding to the #2 IN cylinder can be adjusted. [10] Repeat steps [4] to [8] above. [11] Remount the ignition plugs, the air hose, and the igniter connectors. [12] Disconnect the mixer - head cover blowby hose from the head cover, and start the engine. [13] Inject about a half can of valve cleaner from the disconnected blowby hose into the mixer. Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed. WARNING When the engine is running, be extra careful so as not to get your body or clothes caught in movable sections such as pulleys. [14] Reconnect the hose and then after letting the engine run until no white smoke has come out from the exhaust trapper, stop the engine. [15] Confirm compression. If compression is not recovered, repeat steps [1] to [11] above. 3-39 3 TROUBLE DIAGNOSIS AND REPAIR Cleaning with a valve cleaner Intake valve Gas mixer Carbon Combustion chamber Valve cleaner [1] Disconnect the mixer - T pipe blowby hose from the T pipe. [2] Start the engine. [3] Inject about a half can of valve cleaner from the disconnected blowby hose into the mixer. Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed. [4] Reconnect the hose. [5] Let the engine run until no white smoke has come out from the exhaust trapper, and then stop the engine. WARNING Be extra careful so as not to get your fingers, clothes, etc. caught at the pulley or other rotating bodies when cleaning. (9) Mixer fuel valve check Remove the fuel valve harness from the mixer and confirm the resistance values between each connector terminal connection on the stepping motor. Terminal Resistance between Terminals (20°C) B1 – S1 32 ± 2 Ω B1 – S3 32 ± 2 Ω B2 – S2 32 ± 2 Ω B2 – S4 32 ± 2 Ω S1 – S3 64 ± 4 Ω B2 – S4 64 ± 4 Ω Fuel stepping motor Connector 3-40 AISIN Aisin gas heat pump 3.4.4 If the Engine Stalls Trouble Classification of Likely Causes Sub-Classification Check and Remedy Engine stall with the throttle open implies the insufficiency in engine output. E85 (75) display 1) Insufficiency in engine output [1] Fuel circuit malfunction (Inappropriate air-to-fuel ratio) Air cleaner clogging [2] Ignition circuit malfunction Ignition plug malfunction Deposits or moisture Plug gap out of specs. High-tension cord malfunction Improper ignition timing [3] Improper compression Upward valve plunging - Check the air cleaner. - Check the gas-operated solenoid valve. - See “(3) Checking the ignition plugs” in 3.3.3. - See “(4) Checking the high-tension cords” in 3.3.3. - See “(1) Checking and adjusting ignition timing”. - See “(6) Checking for appropriate compression” in 3.3.3. Valve malfunction due to an obstruction - Clean the valve. See “(8) Improving incomplete compression due to an obstruction on the valve seat” in 3.3.3. 2) Throttle control circuit faults [1] Throttle malfunction Stepping motor malfunction Improper output - See “(2) Checking the throttle actuator”. 3) Noise or others [1] Engine speed reading error or incomplete contact of the distributor connector - See “(3) Checking the starter driving circuit for incomplete contact”. [2] Incomplete contact of the 12 VDC terminal/connector connections [3] Malfunction due to ignition circuit induced noise - See “(4) Checking the ignition circuit for noise”. (1) Checking and adjusting ignition timing [1] Connect the timing light pickup clip to the high-tension cord of one cylinder. [2] Radiate timing light to the ignition advancer scale at the top of the rear crank pulley, and confirm ignition timing. Engine Speed –1 1200 min Angle of Advance 16 ± 3° Note: The above is common to 13A and propane gases. 3-41 Timing light 3 TROUBLE DIAGNOSIS AND REPAIR (2) Checking the throttle actuator [1] When the OPERATE switch is turned on, the shaft of the throttle will temporarily operate to fully close the throttle valve and then open it to the specified angle, so as to initialize the stepping motor. Check if the initial operation of the shaft is normal. [2] Measure conducting resistance between connector terminals of the stepping motor. Shaft the * Motor coil conducting resistance values Measuring Point Resistance Value Between white and red Between red and orange Between blue and brown Between brown and yellow 140 Ω Between white and orange Between blue and yellow 280 Ω (3) Checking the starter driving circuit for incomplete contact Incomplete contact of the starter driving terminals may cause engine stall due to noise. Check the following sections, in particular: 1 2 3 Capacitor connection terminals Diode connection terminals and body grounding connection terminals Terminals for cord connection to the starter Starter (4) Checking the ignition circuit for noise Insufficient insertion of the high-tension cord into the connector or internal disconnection of the cord itself may result in sudden engine stall due to noise and/or in malfunction due to an oil pressure or coolant temperature alarm whose cause cannot be readily identified. [1] Check that the high-tension cord connectors are connected to the ignition plugs and the ignition coils properly. [2] Measure the internal resistance between the high-tension cord terminals and check for abnormality such as disconnections. High-tension cord No. 1 5.7 ± 2.2 High-tension cord No. 2 4.6 ± 1.8 High-tension cord No. 3 3.5 ± 1.3 kΩ (at 20°C) 3-42 AISIN Aisin gas heat pump 3.4.5 Coolant Temperature Alarms Trouble Classification of Likely Causes Sub-Classification Check and Remedy Insufficient circulation of the coolant causes a significant temperature difference between the inlet and outlet of the radiator. E80 (80) display 1) Insufficient circulation of the coolant [1] Shortage, natural evaporation, or leakage of the coolant - See “(1) Checking coolant circulation status”. - See “(2) Checking the coolant level and for leakage”. [2] Coolant pump failure Pump malfunction No output - See “(3) Checking the coolant pump”. [3] Coolant pipeline clogging Thermostat does not open Thermostat malfunction - See “(4) Checking the thermostat”. Although the temperature difference between the inlet and outlet of the radiator is normal, if the temperature of the entire radiator is too high, the heat release capability of the radiator is likely to be insufficient. 2) Insufficient heat release E87 (70) display 3) Sensor or signal line faults 4) Others [1] Radiator intake Too high air temperature Short-circuiting - See “(5) Checking coolant heat release status of the radiator during cooling”. [2] Radiator fin clogging - Clean the radiator fin. [3] Outdoor fan failure Fan motor malfunction No output Fan capacitor malfunction - See “(6) Checking the outdoor fan motors”. - Coolant temperature sensor detection error, malfunction, or incomplete contact or wire disconnections - See “(7) Checking the coolant temperature sensor”. - Decrease in boiling temperature or malfunction in the radiator cap - See “(8) Checking the radiator cap”. (1) Checking coolant circulation status A decrease in the amount of coolant circulation due to pipeline clogging causes a significant temperature difference between the inlet and outlet of the radiator. Confirm this temperature difference to judge whether the circulation of the coolant is normal. During operation, also confirm the sensor-detected temperature (engine exit coolant temperature) in the monitoring data indicating mode of the maintenance board functions. Approximate temperature difference (deg) between radiator inlet and outlet Operating Conditions Cooling 16 to 23 Rated Heating 18 to 25 Rated During operation of Model J/P280 (2) Checking the coolant level and for leakage [1] Check the coolant level in the reservoir. [2] Remove the radiator cap and check if the coolant level is at the upper limit mark. CAUTION - Be sure to use a genuine coolant (Aisin Coolant S, condensation 65%). 3-43 3 TROUBLE DIAGNOSIS AND REPAIR (3) Checking the coolant pump [1] Confirming coolant pump output Check the maintenance board and the outdoor unit circuit board terminals and make sure that an output voltage of 200 VAC is supplied during operation. If, in spite of the fact that the corresponding LED on the maintenance board is on, the required output voltage is not supplied, the switching circuit on the board is likely to be faulty. [2] Checking the coolant pump body Check for normal operating sounds. If the pump does not operate, confirm the resistance values of the motor coils. Motor coil reference resistance value = 58.4 Ω ± 10% Black White Coolant pump (4) Checking the thermostat If, despite the coolant pump being normal, the circulation rate of the coolant is not normal, the thermostat may not have opened properly. Check the operation of the thermostat. Lift amount (mm) Thermostat 1 (Opening start: 62°C) Thermostat changeover temperature Opening start: 62°C Lifting amount: 12 mm Full-opening: 72°C Lifting amount: 18.5 mm (5) Checking coolant heat release status of the radiator during cooling Canopy top Although the temperature difference between the inlet and outlet of the radiator is normal, if the temperature of the entire radiator is too high, perform the following checks: [1] Check for significant increases in the ambient temperature of the radiator due to short-circuiting or other unusual events. [2] Check the radiator fins for clogging and dirt. 3-44 If shrot-circuited Radiator Hot air from the outdoor unit located next to the fans AISIN Aisin gas heat pump (6) Checking the outdoor fan motors If the outdoor fans are not functioning properly, check them as directed below. Note: The number of fans to be operated is controlled during low-temperature cooling and high-temperature heating. [1] Check that an output voltage of 200 VAC is properly developed at the output of the CN13 connector on the outdoor unit circuit board. [2] Measure the fan motor coil resistances at the connector terminals (relay connector). Coil resistance values between fan motor terminals [22.4 kW, 28.0 kW] FM1 FM2 White - Black Black - Yellow White - Black Orange - Red Red - Black 24.6 ± 10% 60.9 ± 10% 24.6 ± 10% 35.2 ± 10% 25.7± 10% Ω White - Black Black - Yellow White - Black Orange - Red Red - Black 17.4 ± 10% 17.3 ± 10% 17.4 ± 10% 6.4 ± 10% 11.0± 10% Ω [35.5 kW] FM1 FM2 Note: If the coil resistances are infinite, thermal fuses are likely to be functioning. [3] Checking the fan capacitor Connect an insulation voltage tester across the fan capacitor within the outdoor unit control box and check the transient characteristics of the resistance value. 10 Ω or more Time Tester Depends on the capacity of the capacitor. Fan capacitor (7) Checking the coolant temperature sensor Check the connector for backlash and improper electrical contact. Also, measure the resistance values between the coolant temperature sensor terminal and body and the coolant temperature (bypass pipe surface temperature) and examine for significant deviations from reference characteristics. Characteristics of the coolant temperature sensor Temperature Resistance 50°C 80°C 100°C 110°C 17.6 kΩ 6.1 kΩ 3.3 kΩ 2.5 kΩ 3-45 3 TROUBLE DIAGNOSIS AND REPAIR (8) Checking the radiator cap [1] Make sure that the seal packing is free from cracking, deformation, and other defects. [2] Make sure that the operating pressure at the radiator cap is within 0.05 ± 0.01 MPa. Seal packings Radiator cap tester Cap tester Adapter 3.4.6 Oil Pressure Alarms Trouble E81 (81) display Classification of Likely Causes 1) Decrease in oil pressure Oil pressure alarm Sub-Classification Check and Remedy If the oil pressure decreases during operation [1] Shortage of oil Oil leakage Unusual oil consumption - See “(1) Checking oil consumption”. [2] Oil line clogging Oil strainer clogging - See “(2) Checking the oil pressure”. 2) Sensor signal circuit faults [1] Oil pressure switch malfunction Sensor fault Improper contact - See “(3) Checking the oil pressure switch”. 3) Noise, others [1] Ignition system Improper contact - See “(4) Checking the ignition circuit for noise” in 3.3.4. [2] Starter driving system Improper contact - See “(4) Checking the starter driving circuit for improper electrical contact”. (1) Checking oil consumption Estimate engine oil consumption from the decrement in oil level and the previous maintenance result data. Consumption = (cm3/h) A change in oil level (mm) × 132 Hours of operation (h) Standard value: 1.0 to 3.0 cm3/h Excessive consumption causes carbon to accumulate at the electrodes of the ignition plugs, resulting in an engine starting failure due to incomplete ignition. In such a case, driving valve parts (stem seals) and piston rings are likely to be malfunctioning. (2) Checking the oil pressure If the oil strainer clogs and the oil is not supplied properly, the required oil pressure will not be obtained. Apply a pressure gauge to the mounting hole (PT1/4) of the oil pressure switch and measure the oil pressure. Also, check the oil level using the oil level gauge. Add 2 to 3 liters of oil if the oil level is too low (near the “L” level mark). Standard value: 0.147 to 0.490 MPa at 1800 min–1 3-46 Oil level gauge AISIN Aisin gas heat pump (3) Checking the oil pressure switch Checking during shutdown [1] Check the oil pressure switch terminals for improper electrical contact due to backlash. [2] Check for normal operation of the oil pressure switch by examining for electrical continuity between the terminals. Engine Status Oil Pressure Switch Terminal Stop Operation Continuity No continuity (4) Checking the starter driving circuit for improper electrical contact Improper electrical contact between the starter driving terminals may cause an oil pressure alarm due to induced noise. Check the following sections, in particular: 1 Capacitor connections 2 Diode connection terminals and body grounding connection terminals 3 Terminals for cord connection to the starter and others 3.4.7 Engine Speed Too High Alarm Trouble E82 (82) display Classification of Likely Causes Throttle returning failures Sub-Classification [1] Throttle lever malfunction Mixer throttle failure [2] Stepping motor malfunction Trouble with the stepping motor itself 3-47 Check and Remedy - Check the operation of the throttle. 3 TROUBLE DIAGNOSIS AND REPAIR 3.4.8 High-Pressure Alarms During Cooling Trouble E40 (76, 86) Refrigerant high-press ure alarm During cooling Classification of Likely Causes 1) Heat exchange inside the condenser of the out-door unit is obstructed. Sub-Classification Check and Remedy [1] Outdoor fan failure Presence of an obstruction (Interference) No output Fan motor malfunction Fan capacitor fault - See “(1) Checking the refrigerant high-pressure level”. [2] - Clean the heat exchanger fins. Deteriorated heat exchange capability Heat exchanger fin clogging or interference [3] Too high intake air temperature Severe environmental conditions or installation status Short-circuiting or others 2) Refrigerant [1] Inappropriate amount of refrigerant circuit faults Overfilling [2] Refrigerant flow channel clogging Check valve sticking Pipeline clogging or breakage Ball valve malfunction (or not fully open) - See “(6) Checking outdoor fan motors” in 3.3.5. - See “(2) Confirming the operating environmental conditions”. - See “(3) Checking the check valve angle”. - Repair the faulty section. - Check if the ball valve is fully open. [3] Entry of uncondensed gas into the refrigerant circuit 3) Sensor or signal line faults [4] Indoor unit electronic expansion valve malfunction - See “(6) Checking the electronic expansion valves”. [5] Liquid flow regulating valve malfunction - See “(4) Checking the liquid flow regulating valve in 3.3.11. [1] Refrigerant high-pressure switch malfunction - See “(4) Checking the refrigerant Refrigerant high-pressure switch high-pressure switch”. circuit fault, improper contact, or wire disconnections [2] High-pressure switch malfunction High-pressure switch circuit fault, improper contact, or wire disconnections 4) Engine [1] Throttle returning failure Throttle lever malfunction or circuit faults stepping motor malfunction - See “(5) Checking the refrigerant high-pressure sensor”. - Check the throttle operation. (1) Checking the refrigerant high-pressure level Measure refrigerant pressure levels from the high-pressure detection ports on the right side of the engine room. If measured data oversteps the ranges listed below, the heat exchange section of the condenser or the refrigerant circuit is malfunctioning. Operating refrigerant pressure values for reference only (during operation of Model P280) Mode Low Pressure Cooling 0.35 to 0.66 MPa Heating 0.36 to 0.81 MPa High Pressure 1.67 to 2.45 MPa 2.11 to 2.40 MPa 3-48 Outside Air Temp. Room Temp. 20 to 40°C 27°C 0 to 15°C 21°C AISIN Aisin gas heat pump (2) Confirming the operating environmental conditions Check for unusual increases in the intake air temperature of the outdoor air heat exchanger due to short-circuiting or other effects of external or peripheral system components. Maximum Permissible Operating Temperature Intake air temperature of the outdoor air heat exchanger 43°C (3) Checking the check valve angle Clogged check valve in the refrigerant room causes the flow of the refrigerant to stop inside the condenser, thus leading to increases in refrigerant pressure due to the shortage of the heat release area. Measure the pipeline temperatures in front of and at the rear of the check valve, and if there is a significant temperature difference of 5 deg or more, replace the check valve since it is clogged. (4) Checking the refrigerant high-pressure switch [1] Checking the refrigerant high-pressure switch for continuity Check for continuity between connector terminals under a stopped status. If continuity is not detected or if it is interrupted by applying shocks to the switch body, replace the switch since its contact points are malfunctioning. Temprerature difference between these positions Check valve [2] Checking the refrigerant high-pressure switch for normal operation While performing continuity checks from the connector terminals and based on the pressure data from the high-pressure detection ports, measure the pressure applied when the switch operates (continuity is lost). The switch is normal if it turns off at 2.8 MPa. Sensor Switch (5) Checking the refrigerant high-pressure sensor [1] Comparing pressures under a stopped status Confirm on the maintenance board the pressure detected by the high-pressure sensor, and compare this value with the pressure indicated by a high-pressure gauge. High-pressure level: Code No. 60 on maintenance board Use a properly calibrated gauge to perform measurements, and zero-adjust the gauge before starting the measurements. a) The sensor is normal if the difference in pressure is within ±0.1 MPa. b) If the pressure displayed on the maintenance board is between 0.0 and 0.1 MPa (in spite of the gauged pressure being higher), check for connector disconnections and proceed to step [3] below. c) If the pressure displayed on the maintenance board is 2.9 MPa or more, skip to step [5] below. d) In cases other than b) and c) above, check pressure with the system in operation and then proceed to step [2] below. [2] Comparing pressures under the operational status - The sensor is normal if the difference in pressure is within ±0.15 MPa. - Proceed to step [3] below if the difference is not within ±0.15 MPa Stop the outdoor unit and perform the following checks: [3] Checking the outdoor unit circuit board for improper connector contact Disconnect and reconnect CN7 from the outdoor unit circuit board, and check if the pressure displayed on the maintenance board returns to normal. Perform repairs if improper contact is detected. If the pressure does not return to normal, proceed to step [4] below. 3-49 3 TROUBLE DIAGNOSIS AND REPAIR [4] Confirming the pressure sensor supply voltage Confirm whether the supply voltage to the pressure sensor is within 5 ± 0.5 V (measure the voltage between pins 8 and 4 on connector CN7). - If the voltage is within 5 ± 0.5 V, proceed to step [5] below. - In other cases, replace the outdoor unit circuit board since it is faulty. [5] Confirming the pressure sensor output voltage Measure the voltage developed across the output of the pressure sensor (namely, between pins 3 and 4 on connector CN7). Required pressure (MPa) = (Output voltage – 0.5) Compare the measured value and the pressure indicated by a high-pressure gauge. - If the difference is within ±0.1 MPa, the pressure sensor is normal. In this case, replace the outdoor unit circuit board since it is faulty. - If ±0.1 MPa is overstepped, replace the pressure sensor since it is malfunctioning. (MPa) 3.0 The output voltage value is about 1 V for 1 MPa. 2.0 1.0 0 0.5 1 2 3 3.5 Output voltage (V) (6) Checking the electronic expansion valves (for indoor unit) [1] Checking if the electronic expansion valves open After about 30 minutes of cooling, the electronic expansion valves in indoor units about 10°C higher than the respective heat exchanger temperatures may not open, even during the operation of all indoor units. (Even when an indoor unit has its electronic expansion valve operating properly, the heat exchanger temperature differs by about 5 to 7°C, depending on the type and capacity of indoor unit and on the indoor temperature.) - Proceed to step [2] below if the electronic expansion valves are not open. [2] Confirming the output voltages of the indoor unit circuit board - Measure the voltages developed at the control pins of electronic expansion valve connector CnA (white, 6-pin, 5-conductor). Also, measure how long the voltages are applied. a) Between orange and gray b) Between red and gray c) Between yellow and gray d) Between black and gray* For a) to d) above, after power-on, a voltage of approx. 5 VDC is applied for about 15 sec. (After power-on, a voltage of 5 VDC must be developed for about 8 sec and then after the voltage has temporarily decreased, it must increase to about 5 VDC for about another 8 sec.) *: During measurement using a digital multimeter, voltages from about 3 to 6 VDC must be developed in sequence. - If the above is confirmed, the indoor unit circuit board is normal. - If the electronic expansion valve does not operate (does not generate operating sounds) under a voltage-applied status, proceed to step [3] below. - In the other cases proceed to step [4] below. [3] Checking the electronic expansion valve - Measure with a tester the resistance value between pin connections (see a) to d) below) of the connector at the electronic expansion valve, and if the measured value is 0 ohms or an infinity, replace the coil. The normal value is about 40 ohms. a) Between orange and gray b) Between red and gray c) Between yellow and gray d) Between black and gray 3-50 AISIN Aisin gas heat pump [4] Confirming the opening of the electronic expansion valve - Operate the indoor unit and check for passing sounds of the refrigerant inside the refrigerant pipeline during the operation of the unit. If no passing sounds are heard, the electronic expansion valve is malfunctioning. (However, check the heat exchanger temperature and make sure that the heat exchanger is not in a stopped status for the purpose of antifreezing. Verify that temperature control is not stopped, either.) 3.4.9 High-Pressure Alarms During Heating Trouble E40 During (76, 86) heating Refrigerant high-pressu re alarm Classification of Likely Causes 1) Heat exchange inside the condenser of the in-door unit is obstructed. Sub-Classification Check and Remedy [1] Indoor fan failure Presence of an obstruction (Interference) No output Fan motor malfunction Fan capacitor fault - See “(1) Checking the refrigerant high-pressure level” in 3.3.8. [2] - Clean the air filter. Deteriorated heat exchange capability (Obstructed ventilation) Air filter clogging Heat exchanger fin clogging - Check the indoor fan motor. See (2). - Clean the heat exchanger fins. [3] Too high intake air temperature Severe environmental conditions Short-circuiting or others 2) Refrigerant [1] Inappropriate amount of refrigerant circuit faults Overfilling [2] Refrigerant flow channel clogging Ball valve closed Pipeline clogged, or damaged Check valve clogged [3] Entry of uncondensed gas into the refrigerant circuit Ingress of air [4] Indoor unit electronic expansion valve malfunction (opening failure) [5] Hot-gas bypass valve malfunction Malfunction (opening failure) Sticking [6] Capacity regulating valve malfunction 3) Sensor or signal line faults - Check if the ball valve is fully open. - Repair the faulty section. - See “(3) Checking the check valve angle” in 3.3.8. - See “(6) Checking the electronic expansion valves” in 3.3.8. - See “(1) Checking hot-gas bypass valve during heating”. - See “(4) Checking the liquid flow regulating valve and capacity regulating valve” in 3.3.11. [1] Refrigerant high-pressure switch malfunction - See “(4) Checking the Refrigerant high-pressure switch refrigerant circuit fault, improper contact, or wire high-pressure switch” disconnections in 3.3.8. [2] High-pressure sensor malfunction High-pressure sensor circuit fault, improper contact, or wire disconnections 4) Engine [1] Throttle returning failure Throttle lever malfunction or circuit faults stepping motor malfunction 3-51 - See “(5) Checking the refrigerant high-pressure sensor” in 3.3.8. - Check the throttle operation. See 3.3.7. 3 TROUBLE DIAGNOSIS AND REPAIR (1) Checking hot-gas bypass valve during heating [1] Measure the coil resistance between pins 1 and 8 of connector CN14 on the outdoor unit circuit board. Reference resistance value = 800 Ω [2] After confirming on the maintenance board that the hot-gas bypass valve is open, make sure that the required voltage is applied between pins 1 and 8 of connector CN14 on the outdoor unit circuit board. (Required voltage: 200 VAC) If the required output voltage is not obtained, the board is likely to be faulty. [3] Measure the pipeline temperature at the downstream side of the solenoid valve when seen from the hot-gas bypass valve. - If the hot-gas bypass valve is normal, a temperature slightly lower than the discharge temperature will be obtained. - If the bypass valve is stuck, temperature will not increase when the valve opens. Replace the hot-gas bypass valve if stuck. (2) Fan motor coil resistance See Chapter 6, MAINTENANCE DATA STANDARDS. 3-52 AISIN Aisin gas heat pump 3.4.10 Refrigerant Low-Pressure Alarms Trouble E57 (88) display During cooling Refrigerant low-pressu re alarm Classification of Likely Causes Sub-Classification [1] Indoor fan failure 1) Heat Presence of an obstruction exchange (Interference) inside the No output evaporator Fan motor malfunction of the indoor unit is Fan capacitor fault obstructed. [2] Deteriorated heat exchange capability (Obstructed ventilation) Air filter clogging Heat exchanger fin clogging Check and Remedy - Check the indoor fan motor. See (2) in 3.3.9. - Clean the air filter. - Clean the heat exchanger fins. [3] Too low intake air temperature Short-circuiting or others During 2) Heat exchange heating inside the evaporator of the outdoor unit is obstructed. [1] Outdoor fan failure Presence of an obstruction (Interference) No output Fan motor malfunction Fan capacitor fault [2] Deteriorated heat exchange capability Heat exchanger fin clogging or interference - See “(6) Checking the outdoor fan motors” in 3.3.5 - Clean the heat exchanger fins. - Confirm the operating [3] Too low intake air temperature conditions. Outside air temperature below –10°C [4] Deteriorated double-pipe heat exchanger capabilities Engine coolant channel clogging, Thermo valve malfunction Thermo valve mis-mounting During 3) Inappropriate Shortage of the refrigerant amount of cooling Refilling not enough and refrigerant Refrigerant leakage heating 4) Refrigerant Refrigerant circuit clogging circuit faults Ball valve closed Dryer filter clogged - See “(3) Checking the indoor electronic expansion valve for clogging”. Capacity regulating valve clogged - See “(4) Checking the liquid flow regulating valve and capacity regulating valve” in 3.3.11. Check valve clogged - See “(4) Checking the check valve for clogging”. 5) Low-pressur Refrigerant low-pressure switch malfunction Trouble with the switch itself e switch Incomplete contact or wire faults disconnections 6) Hot gas bypass valve faults - See “(2) Checking the dryer filter for clogging”. Indoor unit electronic expansion valve Liquid flow regulating valve clogged During cooling - See “(1) Checking the amount of refrigerant”. Hot-gas bypass valve malfunction Defects in operation Clogging 3-53 - See “(5) Checking the refrigerant low-pressure switch”. - See “(1) Checking the hot-gas bypass valves during heating” in 3.3.9. 3 TROUBLE DIAGNOSIS AND REPAIR (1) Checking the amount of refrigerant Operate all indoor units and measure refrigerant pressure levels from the high-pressure detection ports provided inside the engine room. If measured data oversteps the ranges listed below, the heat exchange section of the condenser or the refrigerant circuit is malfunctioning. Operating refrigerant pressure values for reference only (during operation of Model P280) Mode Low Pressure Cooling 0.35 to 0.66 MPa Heating 0.36 to 0.81 MPa High Pressure 1.67 to 2.26 MPa 2.11 to 2.26 MPa Outside Air Temp. Room Temp. 20 to 40°C 27°C 0 to 15°C 21°C (2) Checking the dryer filter for clogging Fully or partially clogged dryer filter in front of the expansion valve reduces the refrigerant pressure. Measure the pipeline temperatures in front of and at the rear of the dryer filter, and if measured values significantly differ by 5°C or more, replace the filter since it is clogged. (3) Checking the indoor electronic expansion valve for clogging [1] Turn off the power circuit breaker temporarily and then turn it back on. The indoor electronic expansion valve will repeat full-opening and full-closing actions. Confirm the operating sounds at this time. [2] Disconnect the CnA connector from the indoor unit circuit board and measure coil resistance values between the pin terminals of the driving motor. Pin Connection To Be Measured Reference Resistance Value (±10%) Orange - Red 90 Red - Yellow 90 Yellow - Black 90 Black - Gray 45 Gray - Orange 45 Ω (4) Checking the check valve for clogging Clogged check valve reduces the refrigerant pressure. Measure the pipeline temperatures in front of and at the rear of the check valve, and if measured values significantly differ by 5°C or more, replace the valve since it is clogged. (5) Checking the refrigerant low-pressure switch Confirm electrical continuity between pins 1 and 2 of connector CN8 on the outdoor unit circuit board. If no continuity is detected or if applying a shock to the switch body interrupts continuity, the contacts of the switch are not normal; replace it in that case. Closed (normal) 0.05 0.15 Open (error) Mpa 3-54 AISIN Aisin gas heat pump 3.4.11 Refrigerant Discharge Temperature Alarms Classification of Likely Causes Trouble 1) Too high compressor intake temperature E36 (91) display Discharge temperature alarm Sub-Classification The discharge temperature increases with increases in compressor intake temperature (superheating level). [1] Too high superheating level (Refrigerant undercirculation) Shortage of refrigerant Leakage or mere shortage Refrigerant channel blocking Indoor unit electronic expansion valve malfunction Dryer filter clogging Too high compressor discharge temperature Check valve clogging [2] Hot-gas leakage to intake port Leaks in four-way changeover valve Valve malfunction [3] Injection error Injection shortage Liquid injection valve malfunction Liquid injection pipe clogging 2) Too high condensing pressure 3) Deteriorated compression efficiency Check and Remedy - Check the operational status. - See “(1) Checking the amount of refrigerant” in 3.3.10. - Check the indoor unit electronic expansion valve. See (3) in 3.3.10. - See “(2) Checking the dryer filter for clogging” in 3.3.10. - See “(4) Checking the check valve for clogging” in 3.3.10. - See “(1) Checking the four-way changeover valve”. - See “(4) Checking the liquid flow regulating valve and the capacity regulating valve”. The discharge temperature increases with increases in condensing pressure. [1] Insufficient heat release Indoor air filter clogging during heating Indoor heat exchanger fin clogging during heating Outdoor heat exchanger fin clogging during cooling - Clean the indoor air filter. - Clean the indoor heat exchanger fins. - Clean the outdoor heat exchanger fins. [2] Intake air Inappropriate environmental conditions or short-circuiting during cooling - See “(2) Confirming the operating environmental conditions” in 3.3.8. [3] To refrigerant supply line - Confirm the operational status of the compressor. If, in spite of the compressor rotating at full speed, adequate air conditioning cannot be obtained at low condensing pressure and high evaporation pressure, the compressor is likely to have deteriorated in compression efficiency. Insufficient compression efficiency Compressor malfunction - Confirm the operational status of the compressor. 4) Hot-gas bypass valve malfunction Hot-gas bypass valve malfunction Malfunction (open) Interference due to obstructions - See “(2) Checking the hot-gas bypass valves”. 5) Discharge temperature sensor malfunction Discharge temperature sensor Trouble with the sensor itself - See “(3) Checking the discharge temperature sensor”. Overheating of the compressor body 3-55 3 TROUBLE DIAGNOSIS AND REPAIR (1) Checking the four-way changeover valve Four-way changeover valve malfunction may cause the slide valve to get stuck in its middle position, and if this state persists, the hot gas will leak into the intake port and increase the intake temperature, with the result that the discharge temperature will also increase. [1] Check for unusual operating sounds (clear hissing sounds) from the four-way changeover valve during operation. [2] Check for significant temperature differences between the inlet and outlet of the four-way changeover valve for the low-pressure refrigerant gas. (2) Checking the hot-gas bypass valves [1] Measure coil resistance between pins 1 and 8 of the CN14 connector on the outdoor unit circuit board. Reference resistance value = 800 Ω [2] After confirming on the maintenance board that the hot-gas bypass valves are closed, measure the voltage between pins 1 and 8 of the CN14 connector on the outdoor unit circuit board. If 200 VAC is constantly supplied, the board may be faulty. [3] Measure the pipeline temperatures at the downstream side of the solenoid valves with respect to the hot-gas bypass valves. When the bypass valves are open, temperatures slightly lower than the discharge temperature must be detected. Obstructions may be interfering with the hot-gas bypass valves if the valves are open without 200 VAC being applied. (3) Checking the discharge temperature sensor Confirm the sensor-detected operating discharge temperature using the data display function of the maintenance board, and measure an actual temperature. Judge from these temperatures whether the sensor is normal. Characteristics of the discharge temperature sensor Standard Temperature 0 20 50 °C 80 100 120 Resistance Value 182.9 70.4 20.2 kΩ 7.0 3.7 2.1 3-56 AISIN Aisin gas heat pump (4) Checking the liquid flow regulating valve and the capacity regulating valve [1] Checking the mechanical lock of the liquid flow regulating valve (electronic expansion valve) The motor, when driven with the mechanical section of the liquid flow regulating valve locked, runs idle and generates weak “click” sounds. When the lock is normal, these sounds are heard under the fully closed status of the valve during power-on and no such sounds are heard under the open status of the valve. The lock is abnormal if such sounds are heard under both the fully closed status and open status of the valve. Replace the liquid flow regulating valve in that case. [2] Confirming motor coil resistance values Measure resistances between motor coils (red - white, red - orange, brown - yellow, and brown blue), and make sure that measured values are as listed below. Reference resistance value = 150Ω ± 10% [3] Confirming the continuity of the connectors and wiring After checking for connector disconnections, disconnect the connectors and confirm the continuity of the wiring. 3.4.12 Communications Trouble and Indoor Unit Circuit Trouble Trouble Classification of Likely Causes Communications 1) Indoor and outdoor unit trouble display address E2 (2) display number E3 (3, 4) display errors E4 (–) display E10 (–) display E14 (14) display E31 (31) display E6 (96) display E7 (97) display E8 (8) display Sub-Classification If an unusable address is assigned - Indoor unit address number overlapping - Outdoor unit address number assignment error - Indoor unit address number assignment error - Too many indoor units connected - Sub-unit address number assignment error - Outdoor unit address number overlapping 2) Indoor unit [1] Heat exchange sensor sensor Sensor malfunction short-circuiting Incomplete contact or wire or wire disconnections disconnections [2] Intake sensor Sensor malfunction Incomplete contact or wire disconnections 3) Heating overload alarm [1] Heating overload [2] Indoor unit heat exchanger thermistor malfunction [3] Indoor unit circuit board fault (Thermistor input circuit fault) E9 (95) display 4) Drain water float switch on Check and Remedy [1] Drain water accumulation Drain piping defects Riser or sloped Drain pump failure No output Incomplete contact or disconnections Pump malfunction [2] Float switch malfunction 3-57 - Check the assigned address number. See the item on function select DIP switches. - See “(1) Checking the temperature sensor”. - See “(2) Confirming indoor unit intake status”. - See “(1) Checking the temperature sensor”. - See “(3) Testing for normal drainage”. - See “(4) Checking the drain pump”. - See “(5) Checking the float switch”. 3 TROUBLE DIAGNOSIS AND REPAIR (1) Checking the temperature sensor Confirm the sensor-detected temperature using the data indication function of the maintenance board, and measure an actual temperature. Judge from these temperatures whether the sensor is normal. Judgment criteria for temperature sensor Standard Resistance (kΩ) 29.1 16.8 10.0 6.2 4.0 2.6 1.8 Temperature (°C) -10 0 10 20 30 40 50 (2) Confirming indoor unit intake status Make sure that the intake port of the indoor unit is free from blocking, that the filter is not clogged, and that the fan motors operate properly. (3) Testing for normal drainage [1] Slowly supply about 1 liter of water seeing the left view below: [2] Connect the remote control switch and start the system in cooling mode. When the compressor is turned on, the drain pump will start rotating. [3] Test for normal drainage while confirming the rotating sounds of the drain pump. Insert about 20 to 30 mm of a water hose facing downward, and supply water. Body Drain pipe Drainage status can be confirmed through the transparent socket. Remove the grommet. Remount it after the test. The water may not be drained from the drain pipe even though the drain pump is in operation, or the possible backflow of the water, associated with the stop of the pump, may result in an error. The situation under which these events may occur is shown below. (4) Checking the drain pump [1] Confirming the operating sounds of the pump Confirm the operation of the pump by judging from its operating sounds and from the flow of the water through the pipe. [2] Confirming the output voltage If the drain pump is not functioning, check for an output voltage of 200 VAC at the output terminals of the indoor unit circuit board. [3] Checking the drain pump motor Measure coil resistances between lead-wired terminals, and scan for disconnections and short-circuiting. Type of Indoor Unit Reference Resistance Values TKTP (4-way cassette type) TKTWP (2-way cassette type) TKRP (Built-in cassette type) TKTSP (1-way cassette type) TKUMP (Medium static-pressure duct type) 212 Ω 136 Ω 327 Ω 3-58 AISIN Aisin gas heat pump (5) Checking the float switch Confirm the electrical conducting status of the float switch (FS). Normal Abnormal Conducting Not conducting Note: Error code E9 will be displayed if the switch wiring is disconnected or if the switch itself is not connected. 3.4. 13. If Sufficient Cooling Cannot Be Obtained Trouble Classification of Likely Causes Sub-Classification Insufficient 1) Electromagnetic [1] Electromagnetic clutch malfunction clutch of the Trouble with the clutch itself cooling compressor is Incomplete contact not engaged. No output Control section [2] Indoor temperature sensor malfunction Incomplete contact or wire disconnections Sensor fault Check and Remedy - See “(1) Checking the electromagnetic clutch”. - See “(1) Checking the temperature sensor” in 3.3.12. (Adequate air conditioning cannot be obtained since the indoor temperature is mis-judged to be lower than its actual value.) [3] Heat exchanger temperature sensor Incomplete contact or wire disconnections Sensor fault - See “(1) Checking the temperature sensor” in 3.3.12. (Since the heat exchanger temperature is mis-judged to be lower than its actual value, the antifreezing control function operates during cooling.) 2) Electromagnetic [1] Automatic activation of refrigerant circuit - Confirm circuit protector clutch of the protector status. compressor is engaged. No error is displayed until the refrigerant circuit protector has repeated its automatic activation and automatic resetting several times. During this automatic resetting cycle, therefore, the clutch is repeatedly engaged and disengaged. [2] Extreme decrease in indoor heat exchanger temperature Expansion valve clogging Dryer filter clogging Other clogged/blocked status (The antifreezing control function of the indoor heat exchanger operates.) 3) Improper indoor [1] Insufficient ventilation Indoor unit air filter clogging unit heat Heat exchange fin clogging exchange [2] Improper indoor fan motor rotation Abnormal output voltage Fan capacitor malfunction Fan motor malfunction 3-59 - See “(3) Checking the indoor electronic expansion valve for clogging” in 3.3.10. - See “(2) Checking the dryer filter for clogging” in 3.3.10. - Clean the indoor unit air filter. - Check the indoor fan motor. See 3.3.9. 3 TROUBLE DIAGNOSIS AND REPAIR Trouble Classification of Likely Causes 4) Compressor rotates, but cold air is not supplied. Sub-Classification [1] Shortage of refrigerant Underfilling Refrigerant leakage [2] Refrigerant circuit fault Four-way changeover valve body malfunction Others [3] Indoor unit electronic expansion valve malfunction [4] Hot-gas bypass valve does not close Insufficient 5) Engine speed does not cooling increase (during a mode such as error avoidance control). 6) Installation status is not appropriate. Check and Remedy - Check the operational status. - See “(1) Checking the amount of refrigerant” in 3.3.10. - See “(2) Checking the four-way changeover valve”. - See “(6) Checking the electronic expansion valves” in 3.3.8. - Check the hot-gas bypass valve. [1] High-pressure error avoidance - See high-pressure error check items. [2] Discharge temperature error avoidance - See discharge temperature error check items. [3] Coolant temperature error avoidance - See coolant temperature error check items. [4] Insufficiency in engine output Engine starts, but it stalls. - See engine stall check items. [1] Significant loss of pressure in the piping Piping between indoor and outdoor units is too long. Too many bends are present. Branched piping is too long. Piping size is not appropriate. [2] Significant difference in elevation [3] Piping branches The branch pipe is not mounted at the correct angle. The branched header is further branched. [4] The total connection capacity of the indoor units is too large. - Actual length: 100 m (max.) - Equivalent length: 125 m (max.) - Length from the first branch: 40 m (max.) - Between indoor and outdoor units (max.) Outdoor unit upper: 50 m Outdoor unit lower: 40 m - Difference in elevation between indoor units: 15 m (max.) - Approx. 130% or less (Capability decreases in proportion to the excess amount of capacity.) (1) Checking the electromagnetic clutch [1] Confirming output voltage Measure the output voltage (12 VDC) between outdoor unit circuit board output terminals (CON11 pin 2 and frame ground). If, in spite of the fact that the corresponding LED on the maintenance board is on, the required output voltage is not supplied, the switching circuit on the board is likely to be faulty. [2] Checking the electromagnetic clutch Measure the conducting resistance between the connector and frame ground terminal of the electromagnetic clutch, and check for coil disconnections. Note: Disconnect the connector before measuring the conducting resistance. (2) Checking the four-way changeover valve If the four-way changeover valve does not shift from heating mode, hot air will be supplied, even during operating in cooling mode. Such a state implies that the output voltage remains applied to the electromagnetic coil or that the valve inside the main unit is malfunctioning. 3-60 AISIN Aisin gas heat pump 3.4.14 If Sufficient Heating Cannot Be Obtained Trouble Classification of Likely Causes Sub-Classification Insufficient 1) Electromagnetic [1] Electromagnetic clutch malfunction Trouble with the clutch itself clutch of the heating Incomplete contact compressor is No output Control section not engaged. [2] Indoor temperature sensor malfunction Short-circuiting Sensor fault Check and Remedy - See “(1) Checking the electromagnetic clutch” in 3.3.13. - See “(1) Checking the temperature sensor” in 3.3.12. (Adequate air conditioning cannot be obtained since the indoor temperature is mis-judged to be higher than its actual value.) - Confirm circuit protector 2) Electromagnetic [1] Automatic activation of refrigerant circuit clutch is protector status. disengaged immediately No error is displayed until the refrigerant circuit protector has repeated its after being automatic activation and automatic resetting several times. During this engaged. automatic resetting cycle, therefore, the clutch is repeatedly engaged and disengaged. 3) Improper indoor unit heat exchange 4) Sufficient compressor capabilities cannot be obtained. [1] Insufficient ventilation Indoor unit air filter clogging Heat exchange fin clogging - Clean the indoor unit air filter. [2] Improper indoor fan motor rotation Abnormal output voltage Fan capacitor malfunction Fan motor malfunction - Check the indoor fan motor. See 3.3.9. First, measure the refrigerant pressure and temperature during operation and check the refrigerant cycle. [1] Insufficient heat exchange in evaporator Hot-water heat collection failure Continued flow of coolant into radiator Thermostat malfunction Coolant circuit clogging Failure to collect heat from hot air supply Insufficient ventilation Outdoor fan failure Fin clogging Short-circuiting Too low intake air temperature [2] Insufficient circulation of refrigerant Shortage of refrigerant Underfilling Refrigerant leakage Refrigerant channel clogging Expansion valve sticking Dryer filter clogging [3] Indoor unit electronic expansion valve malfunction [4] Hot-gas bypass valve does not close 3-61 - Check the operational status. - Check the thermo valve. See (4) in 3.3.5 and (1) in 3.3.12. - See “(6) Checking outdoor fan motors” in 3.3.5. - Clean the heat exchanger fins. - See “(1) Checking the amount of refrigerant” in 3.3.10. - See “(3) Checking the indoor electronic expansion valve for clogging” in 3.3.10. - See “(2) Checking the dryer filter for clogging” in 3.3.10.motor. - See “(6) Checking the electronic expansion valves” in 3.3.8. - Check the hot-gas bypass valve. 3 TROUBLE DIAGNOSIS AND REPAIR Trouble Classification of Likely Causes Insufficient 5) Engine speed does not heating increase (during a mode such as error avoidance control). Sub-Classification [1] High-pressure error avoidance - See high-pressure error check items. [2] Discharge temperature error avoidance - See discharge temperature error check items. [3] Coolant temperature error avoidance - See coolant temperature error check items. [4] High-pressure error detection Refrigerant high-pressure sensor malfunction - See “(5) Checking the refrigerant high-pressure sensor” in 3.3.8. (Engine speed does not increase since the high-pressure level has been mis-detected as being too high.) [5] Insufficiency in engine output Engine starts, but it stalls. 6) Installation status is not appropriate. Check and Remedy [1] Significant loss of pressure in the piping Piping between indoor and outdoor units is too long. Too many bends are present. Branched piping is too long. Piping size is not appropriate. [2] Significant difference in elevation [3] Piping branches The branch pipe is not mounted at the correct angle. The branched header is further branched. [4] The total connection capacity of the indoor units is too large. 3-62 - See engine stall check items. - Actual length: 100 m (max.) - Equivalent length: 125 m (max.) - Length from the first branch: 40 m (max.) - Between indoor and outdoor units (max.) Outdoor unit upper: 50 m Outdoor unit lower: 40 m - Difference in elevation between indoor units: 15 m (max.) - Approx. 130% or less (Capability decreases in proportion to the excess amount of capacity.) AISIN Aisin gas heat pump 3 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS Chapter 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4.1 Engine Body Replacement 4.2 Cylinder Head Replacement 4.3 Compressor Replacement 4-1 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4.1 Engine Body Replacement (1) Components, tools, and materials required Description Components Tools Part No. Qty. 1 1 622041-33020 G0954-3252 622461-30010 Engine assy set Aisin Coolant S Aisin Gas Engine Oil L-10000 4 — — — — — Hose clipper Belt tension gauge Timing light Torque wrench Wooden piece (2) Disassembly procedure [1] Remove the compressor belt. [2] Drain the engine oil. See Fig. 1. 1) Clamp the engine - oil sub tank oil hose using hose clippers. 2) Remove the plug of the oil pan and drain the oil using an oil changer. Or remove the joint and drain the oil. 3) Also, drain out the oil from the oil sub-tank similarly. 4) Remove the engine - oil sub-tank oil hosing (3 pieces) from the engine. Oil hose Oil hose clamping position Plug Joint Fig. 1 [3] Drain the coolant. See Figs. 2 and 3. 1) Clamp the coolant hosing in two places. 2) Loosen the coolant drain plug and drain the coolant. 3) Remove the coolant hosing (2 pieces) from the engine. [4] Remove the harness. See Figs. 2 and 3. 1) 2) 3) 4) 5) 6) Starter (2 places) Gas mixer (2 places) Engine speed sensor Engine oil pressure switch Ignition coil (3 places) Coolant temperature sensor Coolant hose clamping position Engine speed sensor Gas mixer Coolant temperature sensor Starter Engine oil pressure switch Fig. 2 [5] Remove the exhaust heat exchanger. See Fig. 4. Loosen the bolts on the exhaust pipe and exhaust heat exchanger mounting stay, and remove the exhaust heat exchanger. When removing the exhaust heat exchanger, suspend it with strings or other slings. Otherwise, the exhaust heat exchanger will be unstable. Ignition coil Coolant drain plug [6] Remove the compressor. See Fig. 4. 1) Suspend the compressor with strings or other slings. 2) Remove the bracket mounting bolts and remove the compressor together with the bracket from the engine. 4-2 Engine bracket Fig. 3 AISIN Aisin gas heat pump [7] Remove the engine. See Fig. 4. Exhaust pipe 1) Remove the air suction hose. 2) Remove the oil pan from the bottom of the engine. Suction hose Compressor Compressor 3) Insert a wooden piece (about 20 mm thick) under the engine. 4) Remove the engine brackets (3 pieces) and then remove the engine by pulling it to the front. [8] Check the compression is the specific value or more by the compression gauge. Compressor bracket Compressor bracket Engine bracket Engine bracket Fig. 4 The specific pressure = 1.4 MPa or more [9] After removing the hose clipper, open the radiator cap and fill the radiator with the coolant. Condensation of coolant = 65 % (Volumetric concentration) [10] After operating the coolant pump with the “Check mode #34, water filling mode, check the amount of coolant in the radiator cap and, if the water level is lower, fill it with the coolant. [11] Until not checking the decline of the water level like in [10], repeat the performance in the [10] [12] Operate the engine and check the oil leakage, water leakage and other errors. (3) Reassembly procedure [1] Connect the gas mixer, the exhaust manifold, the compressor pulley, and the blowby hose to a new engine. Replace the gaskets of the gas mixer and exhaust manifold. Compressor pulley tightening torque: 39 Nm [2] Mount the engine in the reverse order to that of removal. Replace the gasket of the exhaust pipe with a new one. Note: When placing the engine on the ground, lay out waste cloths and slowly rest the engine on them taking care not to damage the bottom of the oil pan. Compressor belt tension: 550 N to 600 N [3] After removing all hose clippers, open the radiator cap and add coolant until the radiator has become full. Coolant concentration: 65% (Volumetric concentration) [4] Add the specified amount (35 liters) of new engine oil from the oiling port of the oil sub-tank. [5] After driving the coolant pump in “Check Mode - #34 Refilling Mode” of the maintenance board, open the radiator cap and check the coolant level in the radiator. Refill the radiator if the coolant level is too low. [6] Repeat step [5] above until the coolant level in the radiator has stopped decreasing. [7] Start the engine and check for oil leakage, coolant leakage, and other abnormalities. [8] Stop the engine and after waiting for at least 10 minutes, pull out the oil level gauge of the oil sub-tank and check the oil level. Specified amount = FULL level + 0 to 20 mm 4-3 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS 4.2 Cylinder Head Replacement (1) Components, tools, and materials required Description Components Materials/Others Tools Part No. Cylinder head set Aisin Coolant S Aisin Gas Engine Oil L-10000 Gasket remover Waste cloth Hose clipper Scraper (Iron pawl) Belt tension gauge Torque wrench Plug wrench 622043-33020 G0954-3252 622461-30010 Qty. 1 1 Small quantity — — — — — — — (2) Disassembly procedure [1] Drain the coolant. See Figs. 1 and 2. 1) Clamp the coolant hose in two places. 2) Loosen the coolant drain plug and drain the coolant. 3) Remove the coolant hosing (2 pieces) from the engine. Coolant hose clamping position Exhaust manifold Exhaust pipe Suction hose Gas mixer Coolant temperature sensor Oil hose [2] Remove the harness. See Figs. 1 and 2. 1) Gas mixer (2 places) 2) Ignition coil (3 places) 3) Coolant temperature sensor [3] Remove the high-tension cords and remove the ignition plugs. Heat exchanter bracket Fig. 1 [4] Loosen the three nuts and remove the cylinder head cover. Ignition coil [5] Loosen the three nuts, then remove the rocker shaft assembly, and remove the stem cap. See Fig. 3. Note: Be careful at this time so as not to drop the stem cap into the engine. Coolant drain plug [6] Remove the push rods. Note: After removing the rods, arrange them in order of removal. [7] Remove the exhaust heat exchanger stay from the exhaust manifold. [8] Remove the exhaust pipe. Fig. 2 Valve stem cap [9] Remove the air suction hose and the oil hosing. [10] Loosen the 14 bolts and remove the cylinder head. Fig. 3 4-4 AISIN Aisin gas heat pump (3) Reassembly procedure [1] Mount accessories in/on a new cylinder head. See Fig. 4. 1) Intake manifold (Replace the gasket.) 2) Exhaust manifold (Replace the gasket.) 3) Ignition coils (The #2 coil has bolts at its reverse side as well.) 4) Water inlet and water outlet (Replace the gasket.) 5) Hosing 6) Stud bolts [2] Remove all fragments of the old gasket and dirt from the surface of the cylinder block using a scraper and a gasket remover. Notes: 1. Do not allow dirt to enter the oiling port, the coolant holes, or the boltholes. 2. Use a gasket remover only for metallic sections. 3. If the bolts are tightened with the boltholes filled with oil or coolant, the resulting overflow may deteriorate the seal ability of the gasket. Before tightening the bolts, therefore, be sure to wipe with a waste cloth. [3] Place the gasket on the cylinder head and then mount the cylinder head. Tighten the 14 bolts in the numerical order shown in Fig. 6, and in two split operations. See Figs. 5 and 6. Tightening torque: IN manifold Water outlet Water inlet Fig. 4 Knock pin hole Front Fig. 5 34 Nm [4] Insert the push rods in the order that they were removed. [5] Mount the stem cap on the valve and then mount the rocker shaft assy. See Fig. 7. Note: Tighten the nut so that the adjust screw fits into the cup of the push rod. Rocker shaft assembly fastening torque:20 Nm [6] Adjust the valve clearance. Fig. 6 Clearance adjustment value: 0.25 ± 0.05 mm [7] Remount the following removed parts: 1) 2) 3) 4) 5) 6) Head cover Air suction hose and oil hosing Exhaust pipe (replace the gasket) Exhaust heat exchanger stay Ignition plugs and high-tension cords Harness (Gas mixer, ignition coils, and coolant temperature sensor) 7) Coolant hosing Fig. 7 4-5 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS [8] Measure compression force using a compression gauge. Specified compression force: 1.4 MPa or more [9] After removing all hose clippers, open the radiator cap and add coolant until the radiator has become full. Coolant concentration: 50% (Volumetric concentration) [10] After driving the coolant pump in “Check Mode - #34 Refilling Mode” of the maintenance board, open the radiator cap and check the coolant level in the radiator. Refill the radiator if the coolant level is too low. [11] Repeat step [10] above until the coolant level in the radiator has stopped decreasing. [12] Start the engine and check for oil leakage, coolant leakage, and other abnormalities. 4-6 AISIN Aisin gas heat pump 4.3 Compressor Replacement (1) Components, tools, and materials required Description Components Part No. Compressor Assy (Spare parts kit) Qty. R (variable): 623404-11010 L (fixed): 621030-11010 623187-30010 Dryer filter Materials R407C NL10 — — Tools (except general-purpose tools) - Vacuum pump - Weightometer - Gauge manifold - Belt tension gauge - Digital temperature gauge — — — — — 1 1 (2) Disassembly procedure [1] Remove the compressor. [2] Remove the compressor with the bracket mounted, and then remove the compressor from the bracket. (3) Reassembly procedure Compressor Compressor (Variable) bracket [1] Assemble a new compressor bracket. [2] Remove the port cover of the compressor, and mount new O-rings in the grooves. Note: Coat new O-rings with new refrigerator oil, and mount the O-rings taking care so as not to damage them. – Inlet side 24.4 mm in inside diameter, 2.3 mm in wire diameter – Outlet side (reducing side) 17.4 mm in inside diameter, 2.3 mm in wire diameter Fig. 1 Outlet (Compressor L) [3] Add the required amount of new refrigerator oil from the inlet and outlet ports. See Fig. 2 Refrigerator oil NL10 Amount of oil to be added (for 621030-11020 and 621030-11030) 3 Inlet 3 Inlet: 50 cm , Outlet: 150 cm Note: Refrigerator oil can be easily added by performing this while manually rotating the clutch plate. [4] Place the inlet and outlet ports on the compressor, and tighten bolts to the required torque in the required order (diagonally). (Compressor R) For reducing Bolt tightening torque: 19.6 to 24.5 Nm Outlet Note: When remounting the ports, take care so as not to damage the O-rings. [5] Mount the new bracket to compressor into the position. Mount the belt and adjust belt tension. After this, rotate the compressor through several full turns by hand and check for appropriate belt tension. Belt tension: 550 to 600 N (New belt) 450 to 500 N (After mounting) 4-7 Inlet Fig. 2 4 MAINTENANCE OF MAJOR FUNCTIONAL COMPONENTS [6] After making sure of no refrigerator oil leakage, execute at least one hour of vacuum pumping. When replacing the variable capacity compressor, vacuum the amount adjustment valve with the maintenance board functions like check mode after 1000 Steps or more. [7] Recharge the compressor with refrigerant and refrigerator oil up to the required level. Factory-preset amount of charging: 13 kg Recharge (kg) = (L1 × 0.12) + (L2 × 0.06) + (L3× 0.03) Where L1: Overall length (m) of 12.7mm-diameter liquid pipeline L2: Overall length (m) of 9.52 mm-diameter liquid pipeline L3 Overall length (m) of 6.35 mm-diameter liquid pipeline Notes: When adding refrigerator oil, refer to the section of the MAINTENANCE DATA STANDARDS that describes the compressor circuit. [8] After charging the compressor with refrigerant, check the operation of the compressor by measuring the refrigerant high pressure, low pressure, and temperature. 4-8 AISIN Aisin gas heat pump 3 PERIODIC MAINTENANCE Chapter 5 PERIODIC MAINTENANCE 5.1 Periodic Maintenance Items and Periods 5.2 Periodic Maintenance Procedures 5.2.1 Changing Engine Oils 5.2.2 Replacing the Oil Filter 5.2.3 Replacing an Ignition Plug 5.2.4 Replacing the Air Element 5.2.5 Replacing the Compressor Belt 5.2.6 Adjusting the Valve Clearances 5.2.7 Adding Coolant and Coolant-Strengthening Agent 5.2.8 Checking the Coolant Hosing 5.2.9 Checking the Compressor 5.2.10 Checking the Operational Sounds 5.2.11 Prevention of Valve Damage 5.2.12 Replacing the Fuel Gas Hose 5-1 5 PERIODIC MAINTENANCE 5.1 Periodic Maintenance Items and Periods Periodic maintenance and part replacement are required for continued normal operation of the gas heat pump air-conditioning system. The recommended periodic maintenance and part replacement items for 2,000 hours of operation on an annual basis are listed in the table below. For more hours of annual operation, conduct these items at least every 10,000 hours. WARNING Be absolutely certain to perform the following operations before starting periodic maintenance operations: – Turn off the 200-V ground leakage circuit breaker located inside the control box of the outdoor unit. Before turning off the breaker, stop remote-controlled operation and wait for at least about one minute. – Close the main plug on the fuel line. No. Frequency of maintenance (No. of years) Item To Be Performed 5 10 Changing engine oil 2 Replacing the oil filter 3 Replacing an ignition plug 4 Replacing the air element 5 Checking and replacing the compressor belt 6 Checking the coolant level and adding coolant and coolant reinforcement 7 Checking for engine oil leakage 8 Checking for coolant leakage 1 9 Checking for exhaust gas leakage 10 Checking for fuel gas leakage 11 Checking the compressor 12 Checking for refrigerant leakage 13 Checking for operating sound* 14 Prevention of valve damage* 15 Replacing the gas hose. — 16 Checking and adjusting the valve clearance Notes: 1. After test operation or checking, at five years on a calendar basis or 10,000 hours of actual operation, whichever comes the first, perform maintenance and check operations, subject to the above table. 2. The mark and mark in the table denote replacement and check (adjustment) respectively. Items marked “*” need to be performed with the system running. 3. The mark indicates that carburetor cleaning is required. 4. For the items that require only all-year checking, replace parts when abnormality is detected in the checking operations. 5. Refill the reservoir with the specified amount of coolant-strengthening agent. Use Aisin Coolant S (G0954-3252) of the required concentration to compensate for insufficiency. The required concentration is 65 to 75 percent (coolant: 0.7, water: 0.3), which is equivalent to a concentration of 53 to 60 percent in the case of measurement with an optical concentration meter. 6. Use Aisin Engine Oil L-10000 to add engine oil. 5-2 AISIN Aisin gas heat pump 5.2.1 Periodic Maintenance Procedures Changing Engine Oils [1] Operate the engine for about 5 minutes before changing the oil. [2] After stopping the engine, pull out the level gauge from the oil sub-tank and then drain the oil using an oil changer. Or after clamping the hosing across the joint by use of hose clippers and removing the joint, drain the oil and then return the joint to the original position. 10 (Reference) 5.2 Level gauge Oiling port Joint [3] Add the specified amount (35 liters) of new engine oil from the oiling port of the oil sub-tank. [4] After operating the engine for about 3 minutes, stop the engine and after about 3 minutes, confirm the oil level using the oil level gauge. CAUTION – – – Be sure to use Aisin-specified oil L10000. Keep oils away from belting and pulleys. When clamping the hosing at the joint, confirm the traces of clamping on the hosing and mount it properly at its original position. Changing period At least every 5 years (or 10,000 hours) Oil level F + 0 to 10.0 mm(20 ) F +18 to 9 mm (90 ) 5.2.2 Replacing the Oil Filter [1] Remove the oil filter using an oil filter wrench. Wipe off the dripped oil with a waste cloth. [2] Apply engine oil to the surface of the O-ring in a new oil filter, and be sure to hand-mount the filter securely. O-ring Changing period: At least every 5 years (or 10,000 hours) Tool required: Oil filter wrench 5.2.3 Oil filter Replacing an Ignition Plug [1] Hold the cap of the corresponding high-tension cord and remove the cap. Next, remove the ignition plug using a plug wrench. [2] Mount a new ignition plug; hand-fasten it first and then refasten with a plug wrench. [3] Confirm the identification number of the high-tension cord and mount the cap properly. Changing period: At least every 5 years (or 10,000 hours) Tightening torque: 20 to 25 Nm Tool required: Plug wrench 5-3 Plug Plug wrench 5 PERIODIC MAINTENANCE 5.2.4 Replacing the Air Element [1] Release the four snaps of the air cleaner and then remove the old element. [2] Mount a new element. Mount the element so that the top faces upward. [3] Fasten the four snaps of the air cleaner. Element Snap Changing period: 5.2.5 At least every 5 years (or 10,000 hours) Replacing the Compressor Belt [1] Loosen the bolts, nuts, and adjust bolts to remove the belt. Tension gauge [2] Mount new belt. [3] Adjust belt tension using the adjusting bolts, and fasten the nut. [4] Retighten the bolts. [5] Rotate the engine pulley through several full turns by hand and then check for appropriate belt tension. Reference belt tension: Bolt Nut Adjust bolt 550 to 600 N Compressor belt changing period: At least every 5 years (or 10,000 hours) Tool required: Oil filter wrench: Offset wrenches (12 mm, 14 mm) Belt tension gauge 5-4 Bolt Nut Adjust bolt AISIN Aisin gas heat pump 5.2.6 Adjusting the Valve Clearances [1] Remove the head cover. [2] Match the crank pulley to the top dead center mark as shown in the view. [3] Make sure that when the crank pulley is rotated by about 20 degrees horizontally, the IN rocker arm of the #1 cylinder does not move. If the rocker arm moves, rotate the crank pulley through one full turn for matching to the top dead center. [4] Loosen the adjust nuts on the #1 and #3 intake cylinders and the #1 and #2 exhaust cylinders as shown, and adjust each cylinder. [5] Rotate the crank pulley through 360 degrees. [6] Loosen the adjust nuts on the #2 intake cylinder and the #3 exhaust cylinder as shown, and adjust both cylinders. Reference clearance: 0.35 ± 0.05 mm (hot status) Notes: 1. Do not use thickness gauges of 0.2 mm or more. To adjust clearances of 0.2 mm or more, be sure to use two appropriate gauges in overlapped form. 2. Do not use corroded or bent thickness gauges. 3. When the engine is not cold enough, perform adjustments for a valve clearance that permits a 0.33-mm gauge to be inserted and does not permit a 0.38-mm gauge to be inserted. Rear #3 EX #3 IN #2 EX #2 IN #1 EX #1 IN Top dead center mark Front Front IN 5.2.7 IN EX Front EX Adding Coolant and Coolant reinforcement Agent [1] Refill the reservoir with the specified amount of coolant-strengthening agent. If the specified amount of refilling is likely to cause the FULL level to be exceeded, drain out the coolant from the reservoir beforehand. Frequency of addition Specified amount Reservoir At least every 5 years (or 10,000 hours) 280 to 330 cm3 [2] Add coolant until the FULL coolant level in the reservoir has been reached. CAUTION – – – 5.2.8 Be absolutely certain to use the specified Aisin coolant reinforcement. To add coolant, always use “Aisin Coolant S”. Add coolant at a concentration from 50vol% to 60vol%. Coolant hose Checking the Coolant Hosing Hose clipping Check the coolant hosing (6 pieces) for cracking, deterioration, loose hose clipping, coolant leakage, and other unusual states 5-5 5 PERIODIC MAINTENANCE 5.2.9 Checking the Compressor [1] Check that the compressor does not generate unusual sounds during operation. [2] Make sure that when the electromagnetic clutch is disengaged, the shaft of the compressor does not rotate synchronously. Electromagnetic clutch [3] After stopping the engine, rotate the shaft by hand and check that it rotates smoothly. 5.2.10 Checking the Operational Sounds [1] Check that the outdoor unit does not generate unusual sounds during operation. [2] Listen very carefully for rattling sounds from the cylinder head and for interference sounds from rotating sections around the engine. 5.2.11 Prevention of Valve Damage Cleaning with a valve cleaner Intake valve [1] Disconnect the mixer - T pipe blowby hose from the T pipe. Carbon [2] Start the engine. Combustion chamber [3] Inject about a half can of valve cleaner from the disconnected blowby hose into the mixer. Perform the injection intermittently with care so as not to allow the engine to stall or to overspeed. Gas mixer [4] Reconnect the hose. [5] Let the engine run until no white smoke has come out from the exhaust trapper, and then stop the engine. Valve cleaner WARNING Be extra careful so as not to get your fingers, clothes, etc. caught at the pulley or other rotating bodies when cleaning. 5.2.12 Replacing the Fuel Gas Hose [1] Remove the hose clipping and disconnect the fuel gas hose. Grommet [2] Remount the hose clipping to connect a new hose. Hose regulator Changing period: At least every 10 years (or 20,000 hours) Grommet Bolt with washer O-ring 5-6 Regulator assembly Fuel pipe AISIN Aisin gas heat pump 3 MAINTENANCE DATA STANDARDS Chapter 6 MAINTENANCE DATA STANDARDS 6.1 Engine-Related Components 6.2 Refrigerant-Related Components 6.3 Electrical Equipment 6.4 Coolant-Related Components 6.5 Thermister Characteristics Note: Specifications without Model number of the outdoor unit are common to all models. 6-1 6 MAINTENANCE DATA STANDARDS 6.1 Engine-Related Components Item Standard Value 22.4 kW Engine speed 28 kW 35.5 kW Valve clearance Compression system Compression Ignition timing Ignition system High-tension cord resistance value Ignition plug Idling fuel adjustment (O2 value) P224∗∗P P224∗∗N P280∗∗P P280∗∗N P355∗∗P P355∗∗N Remarks Cooling 1200 - 1600 Heating 1200 - 2150 Cooling 1200 - 1800 Heating 1200 - 2550 Cooling 1200 - 2450 Heating 1200 - 2550 min– 1 Hot status Cold status IN 0.35 0.25 EX 0.35 0.25 Cylinder 1.4 or more Limit 1.1 Tolerance ± 0.05 mm MPa 16 ± 3°/1200 min Cylinder #1 5.7 ± 2.2 Cylinder #2 4.6 ± 1.8 Cylinder #3 3.5 ± 1.3 Gap 0.4 to 0.1 mm Tightening torque 20 to 25 Nm kΩ –1 O2 value 3 to 10 %/1800 min Fuel system Fuel gas pressure Propane 2.8 13A 2.0 6-2 Engine speed of at least 300 min–1 (cranking) Adjustment impossible –1 Ignition timing After stopping the engine being warmed up, perform measurements within 30 minutes. kPa AISIN Aisin gas heat pump Item Engine oil pressure pump Standard Value Relief valve Remarks 0.49 MPa Lubricant system Engine oil amount Type Aisin GHP Oil L10000 (10 L can) Sealing amount 35 L Including oil for the oil filter . Belt tension Compressor belt Initial setting 550 to 600* After mounting 450 to 500 * Manually rotate the engine pulley several times before measuring initial compressor belt tension Tightening torque Cylinder head bolt 34 Nm Compressor pulley bolt 39 Nm Engine pulley bolt 88 Nm Valve rocker shaft nut 19 Nm Cylinder head cover 5.4 Nm After hand-tightening at 2.5 Nm Water drain bolt 12.7 6-3 Nm Use torque wrench without fail. 6 MAINTENANCE DATA STANDARDS 6.2 Refrigerant-Related Components Item Standard Value Compressor oil (Refrigerator oil) NL10 Remarks Outdoor unit body Type R407C Sealing amount Refrigerant gas 4L 13 kg Recharge (kg) (L1 × 0.12) + (L2 × 0.06) + (L3 × 0.03) L1: Overall length (m) of 12.7 mm-diameter liquid pipeline L2: Overall length (m) of 9.52 mm-diameter liquid pipeline L3: Overall length (m) of 6.35 mm-diameter liquid pipeline Refrigerant piping length and permissible difference in elevation 120 (Equivalent length) 100 (Actual length) Piping length Between indoor and outdoor units Outdoor unit lower 40 Outdoor unit higher 50 Between indoor units m 15 For details see the Installation Manual. P224 Refrigerant pipe diameters Flare nut torque values P355 Liquid pipe (mm) φ12.7 φ12.7 φ12.7 Gas pipe (mm) φ25.4 φ28.58 φ31.8 Refrigerant pipe OD (mm) 6.35 1/4 15 to 20 Liquid pipe 9.52 3/8 34 to 39 12.70 1/2 49 to 54 12.70 1/2 49 to 54 15.88 5/8 59 to 64 19.05 3/4 76 to 81 Gas pipe Quantities of refrigerator oil to be added during the repair of refrigerant-relate d sections P280 Nominal diameter (in.) Flare nut tightening torque Nm Description Quantity During replacement of the discharge tubing, the expansion valve, the filter dryer, or other consumable parts in which the refrigerator oil does not accumulate 100 cc During release of waste refrigerant gas 100 cc During replacement of compressor (filter dryer included) Independent replacement (If replacement is made with that of other components, add oil considering other quantities of addition.) 6-4 When refrigerant pipe interior is not to be cleaned 0 cc When refrigerant pipe interior is to be cleaned 1000 cc During replacement of accumulator Residual quantity + 500 cc During replacement of oil separator Residual quantity + 500 cc During replacement of other components (other than compressor) Quantity actually required AISIN Aisin gas heat pump 6.3 Electrical Equipment Item Standard Value Remarks Ignition coil 21 Ω Gas-operated solenoid valve coil Four-way valve coil 1.3 kΩ ± 20% Secondary side Cold status 2.2 to 3.4 Ω (–10 to 50°C) Hot status 2.8 to 4.4 Ω (50 to 100°C) 1100 ± 150 Ω (20°C) Cam angle sensor AC/DC converter transformer Transformer for AC/DC converter Secondary side [6] 4Ω Compressor clutch coil Brown - Blue (1) → 0.5 Ω Brown - Black (2) → 0.6 Ω Blue - Black (3) → 0.3 Ω Secondary side (Reference value) Ignition coil (Primary side) Primary side Coil resistance value Outdoor unit system Primary side [5] [4] (4) → 0.2 Ω (5) → 0.1 Ω (6) → 0.1 Ω Brown Blue [1] 170 Ω Board relay (R2/R3) Black [3] [2] Primary side Motor coil resistance value (Reference value) Indoor unit drain pump *Common to all models 4-/3-/2-way cassette type (TKT)* 212 Ω 2-way cassette type (TKTW)* 212 Ω 1-way cassette type (TKTS)* 136 Ω Built-in cassette type (TKR)* 136 Ω Medium static-pressure duct type (TKUM)* 327 Ω 6-5 6 MAINTENANCE DATA STANDARDS Indoor Unit Fan Motor Resistance Value (Unit: Ω) (1) 4-/3-/2-way blowoff cassette type (TKT) Model Motor Model No. Sub Main 1 Main 2 Main 3 Main 4 P28, P36, P45 SSA511A624A 251.8 165.0 68.5 48.0 48.0 P56 SSA511A625A 246.8 221.5 37.7 31.9 50.0 P71 SSA511A626A 261.9 165.0 52.2 72.5 34.5 P80 SSA511A627A 155.0 175.1 72.6 36.3 36.3 P90, P112 SSA511A628A 57.5 56.8 29.7 13.7 25.1 P140 SSA511A629A 49.3 46.5 21.1 14.0 21.2 P160 SSA511A630A 43.1 34.5 31.5 6.3 21.0 (2) 4-/3-/2-way blowoff compact cassette type (TKTC) Model P22 to P56 Motor Model No. SSA511T094 Sub Main 1 Main 2 Main 3 Main 4 106.0 172.0 62.0 35.0 26.0 (Unit: Ω) (3) 2-way blowoff cassette type (TKTW) Model Motor Model No. (Unit: Ω) Sub Main 1 Main 2 Main 3 Main 4 106.0 172.0 62.0 35.0 26.0 P22 to P56 SSA511T094A P71 SSA511A486CJ 88.6 90.7 46.3 46.3 46.3 P80, P90 SSA511A486B 76.5 134.9 60.5 60.5 60.5 SSA511A486AJ 102.3 69.5 25.5 35.0 35.0 SSA511A487AJ 76.5 134.9 60.5 60.5 60.5 SSA511A486J 54.3 47.3 34.6 44.0 44.0 SSA511A487J 101.0 129.2 49.8 71.2 71.2 SSA511A486AJ 102.3 69.5 25.5 35.0 35.0 SSA511A487J 101.0 129.2 49.8 71.2 61.2 Sub Main 1 Main 2 Main 3 Main 4 P112 P140 P160 (Unit: Ω) (4) 1-way blowoff cassette type (TKTS) Model Motor Model No. P28, P36 SSA511A422J 291.8 158.4 37.8 18.9 18.9 P45, P56 SSA511A305J 69.8 143.0 47.4 47.4 47.4 P71 SSA511A303J 69.2 120.3 64.8 64.8 64.8 (Unit: Ω) (5) Built-in cassette type (TKR) Model Motor Model No. Sub Main 1 Main 2 Main 3 Main 4 P22 SSA511A390 98.1 115.9 9.5 9.5 9.5 P28, P36 SSA511A366J 17.9 34.7 14.5 14.5 14.5 P45, P56 SSA511A349J 83.0 57.1 11.5 11.5 11.5 P71 SSA511A350J 17.9 39.2 14.5 14.5 14.5 P90 SSA511A350AJ 17.9 34.7 14.5 14.5 14.5 SSA511A351J 17.9 39.2 14.5 14.5 14.5 SSA511A352J 83.0 74.0 11.5 11.5 11.5 SSA511A351AJ 17.9 34.7 14.5 14.5 14.5 SSA511A352AJ 83.0 57.1 11.5 11.5 11.5 P112 P140 6-6 AISIN Aisin gas heat pump Indoor Unit Fan Motor Resistance Value (6) Ceiling-embedded high static-pressure duct type (TKU) Model Motor Model No. Sub Main 1 (Unit: Ω) Main 2 P45 to P56 SSA511A471J 35.6 36.3 7.0 P71 to P90 SSA511A358J 35.6 23.7 7.0 P112 SSA511A359J 35.6 16.4 3.5 P140 SSA511A360J 12.6 10.0 6.23 SSA511A363J 35.6 16.4 3.5 P224 P280 SSA511A363J 35.6 16.4 3.5 SSA511A365J 12.6 7.6 4.68 SSA511A364J 12.6 10.0 6.23 (7) Ceiling-embedded medium static-pressure duct type (TKUM) Model (Unit: Ω) Motor Model No. Sub Main 1 Main 2 Main 3 Main 4 P22 SSA511A567 17.9 39.2 14.5 14.5 14.5 P28, P36 SSA511A568 17.9 39.2 14.5 14.5 14.5 P45, P56 SSA511A349J 79.5 55.3 21.4 21.4 21.4 P71 SSA511A350J 17.9 39.2 14.5 14.5 14.5 P90 SSA511A350AJ 17.9 34.7 14.5 14.5 14.5 SSA511A352J 83.0 74.0 11.5 11.5 11.5 SSA511A352AJ 83.0 57.1 11.5 11.5 11.5 SSA511A351J 17.9 39.2 14.5 14.5 14.5 SSA511A351AJ 17.9 34.7 14.5 14.5 14.5 P112 P140 (Unit: Ω) (8) Ceiling-suspended type (TKE) Model Motor Model No. Sub Main 1 Main 2 Main 3 Main 4 P36 to P54 SSA511A305J 291.8 158.4 37.8 18.9 18.9 P71 SSA511A303J 242.0 151.8 58.0 58.0 58.0 P90 SSA511A304J 242.0 151.8 58.0 58.0 58.0 SSA511A307J 236.4 102.5 28.6 28.6 28.6 SSA511A306J 112.9 55.1 9.0 9.0 9.0 SSA511A306J 112.9 55.1 9.0 9.0 9.0 SSA511A306J 112.9 55.1 9.0 9.0 9.0 P112 P140 (Unit: Ω) (9) Wall-mounted type (TKK) Model Motor Model No. Main Sub 1 Sub 2 Sub 3 P28, P36 SSA511B060 231.0 75.0 46.8 186.3 P45 SSA511B047F 131.0 39.1 30.5 77.8 P71 SSA511B047H 131.0 62.3 41.9 187.0 (Unit: Ω) (10) Floor-standing lowboy exposed type (TKFL) Model Motor Model No. Main Sub 1 Sub 2 Sub 3 P28 SSA511B060 231.0 75.0 46.8 186.3 P45, P56 SSA511B047F 131.0 39.1 30.5 77.8 P71 SSA511B047H 131.0 62.3 41.9 187.0 6-7 6 MAINTENANCE DATA STANDARDS Indoor Unit Fan Motor Resistance Value (Unit: Ω) (11) Floor-standing lowboy concealed type (TKFU) Motor Model No. Main Sub 1 Sub 2 Sub 3 P28 Model SSA511T031 130.1 8.5 7.06 56.1 P45, P71 SSA511T031A 72.5 12.1 11.3 28.8 (12) Outside-air processing unit with a direct expansion coil unit (TKSA) (Unit: Ω) Model P28 P45, P56 Motor Model No. Main 1 Main 2 Main 3 Sub PCH511K007 9.9 13.6 45.3 22.7 PCH511K007A 9.9 13.6 45.3 22.7 PCH511K008 5.2 8.4 6.0 3.7 PCH511K008A 5.2 8.4 6.0 3.7 (Unit: Ω) (13) Intake-air processing unit (TKUS) Model Motor Model No. Sub Main 1 Main 2 P90 SSA511A393J 20.3 69.8 — P140 SSA511A394J 12.4 43.2 — Motor Model No. Sub Main 1 Main 2 P80 SSA511A610B 80.0 62.2 6.5 30.8 P140 SSA511A610C 31.6 20.5 7.5 11.3 (Unit: Ω) (14) Floor-standing type (TKF) Model 6-8 Main 3 AISIN Aisin gas heat pump Item Standard Value S – B S – M Starter S B B M – – – – Infinity 0.24 Ω 0.24 Ω Infinity Infinity Body ground M Body ground Body ground 0.01 Ω Terminal S Terminal B Motor coil resistance value (reference) Indoor unit system Terminal M FM1 Outdoor heat exchanger fan motor Black - White 16.61 Ω ± 10% White - Blue 16.61 Ω ± 10% Black - Red 28.36 Ω ± 10% Blue Yellow 23.67 Ω ± 10% Blue - Red 28.36 Ω ± 10% Engine room cooling fan motor Mixer stepping motor FM2 Red - White Red - Orange 170 Ω 140 Ω Brown - Yellow Brown - Blue Yellow - Blue 280 Ω White - Orange B1 – S1 Mixer fuel valve stepping motor B1 – S3 32 Ω B2 – S2 B2 – S4 S1 – S3 64 Ω S2 – S4 6-9 6 MAINTENANCE DATA STANDARDS 6.4 Coolant-Related Components Item Standard Value Remarks Thermostat 1 (Opening start: 62°C) Thermostat valve Temperature Lift amount Opening start 62°C 0 mm Full-open 72°C 6.5 mm Coolant Aisin Coolant S (4 L can) Color Green Coolant Amount 22.4 kW, 28 kW 14 L (including reservoir) 33.5 kW Volumetric concentration Radiator cap Cap pressure 15.5 L (including reservoir) 65 % (–35°C antifreeze liquid) 49 ± 9 6-10 kPa AISIN Aisin gas heat pump 6.5 Thermister Characteristics Item Standard Value Temperature (°C) 50 Coolant temperature sensor Resistance value (kΩ) 17.6 80 6.1 100 3.3 110 2.5 Temperature (°C) Outside air temp. sensor Remarks Resistance value (kΩ) –10 23.7 0 15.0 10 9.8 20 6.5 30 4.4 40 3.1 Accumulator inlet temp. sensor 50 2.2 55 1.86 Compressor intake temp. sensor 60 1.59 Heat exchanger gas temp. sensor 65 1.36 70 1.17 75 1.01 Heat exchanger liquid temp. sensor Temperature (°C) Discharge temp. sensor Resistance value (kΩ) 0 182.9 20 70.4 40 29.9 60 13.9 80 7.0 100 3.7 120 2.1 Temperature (°C) Resistance value (kΩ) –10 29.1 0 16.8 10 10.0 Indoor air temp. sensor 20 6.2 Indoor heat exchanger temp. sensor 30 4.0 40 2.6 50 1.8 6-11 03D224/280/355PM-1 AISIN SEIKI CO., LTD. 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